Reinforced thermoplastic components and method of manufacture thereof

ABSTRACT

Disclosed herein are systems and techniques for producing complex components using a reinforced thermoplastic material. The complex components can include contoured or curved outer surfaces, and in some cases define a cavity. In certain examples, one or more thermoplastic materials are arranged to form a wheel component, such as that adapted to define a rim of the bicycle. Thermal bonding can be used to join multiple reinforced thermoplastic materials to one another in order to form a cavity of the wheel component or other complex shape. In certain examples, a portion of a tooling assembly can be pressurized to maintain a shape of the cavity during thermal bonding and cooling. This can remove the need for a sacrificial bladder or other structure that would maintain the shape of the cavity, allowing for a seamless final component, optionally absent indicia of bladder exit or other seams.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. ProvisionalApplication No. 62/908,320 entitled “Reinforced Thermoplastic Componentsand Method of Manufacture Thereof,” filed Sep. 30, 2019, and to U.S.Provisional Application No. 62/982,611 entitled “ReinforcedThermoplastic Components and Method of Manufacture Thereof,” filed Feb.27, 2020, the disclosures of which are hereby incorporated by referencein their entirety.

FIELD

The described embodiments relate generally to high-strength,light-weight structures formed from reinforced thermoplastic materials,and more particularly, to structures formed from reinforcedthermoplastic materials that can define a hollow cavity.

BACKGROUND

Composite materials can include a combination of two or more distinctmaterials that cooperate in a manner to complement and enhance theirrespective material properties. For example, composite materials caninclude a combination of relatively low weight materials and relativelyhigh strength materials in order to produce components having a highstrength to weight ratio. Such components can include intricate shapesand designs, including shapes tailored for specialty purposes. Specialtypurpose components can, for example, include shapes having contouredsurfaces, such as curved exteriors. Components can also have a hollowinterior for weight reduction. In many traditional systems, thermosetmaterials are used to hold reinforcing materials in a matrix.Traditional approaches can produce overly brittle components, and limitcomponent and manufacturing adaptability. Further, traditionalmanufacturing of components formed from composite materials, andresulting in a shape with a hollow interior, can involve complex,multi-step processes that increase cost and that can result indiscontinuities or inconsistencies. As such, the need continues fortechniques that can enhance the range of composite material componentshapes and structures, without limiting functionality or performance ofoverall design.

SUMMARY

Examples of the present system and method are directed to reinforcedthermoplastic components. More specifically, the examples describedherein are directed to reinforced thermoplastic components havingcomplex shapes, such as a shape having curved contours, substantiallyhollow interiors, and/or other properties. The reinforced thermoplasticcomponents described herein can, in certain examples, be used to form awheel component, such as a wheel used for a bicycle. The reinforcedthermoplastic material can be used to form a completely continuouscircular component that forms a wheel. The wheel component, or otherstructure formed by the reinforced thermoplastic material, can be asubstantially hollow structure. Disclosed herein are techniques forforming the wheel component using one or more reinforced thermoplasticmaterials to form the wheel component having the hollow interior and acurved outer surface, including where the wheel component has asubstantially circular hollow cavity and a continuous circular outershape.

In one example, a wheel component is disclosed. The wheel componentincludes a rim bed portion defining an outer annular surface of thewheel component that is configured to engage a bicycle tire. The wheelcomponent further includes a main structure portion defining a cavitywith the rim bed portion. The rim bed portion and main structure portionare each formed from a reinforced thermoplastic material. The rim bedportion and the main structure are bonded to one another to form anintegral structure.

In another example, the main structure portion can include a wallportion formed from the reinforced thermoplastic material. Thereinforced thermoplastic material of the wall portion can include aplurality of plies overlapping one another and defining a radialcrossply. The plurality of plies can include a first ply having a firstedge. The first edge can define a bias angle of between 22.5 and 75degrees from a center axis of a continuous circle defined by the outerannular surface.

In another example, the plurality of plies can include a second plyhaving a second edge. The second ply can overlap the first ply with thefirst and second edges being substantially transverse to one another. Insome examples, the first and second plies can define an arrangement ofplies. The wheel component can further include a plurality of thearrangement of plies disposed in a radial pattern to define the wallportion.

In another example, the rim bed portion and main structure portion canbe at least one of thermally bonded, chemically bonded, or adhesivelybonded.

In another example, the main structure portion can define an innerannular surface of the wheel component that is configured to receive aseries of spokes. The main structure portion can be configured towithstand a pull force associated with the series of spokes of at least300 lbs. The main structure portion can define a reinforcing layer alongthe inner annular surface.

In another example, the reinforced thermoplastic material includes athermoplastic material and fibers held within the thermoplasticmaterial. The fibers can include one or more of carbon fibers, glassfibers, Kevlar fibers, or basalt fibers. In some examples, the fiberscan define at least 30% of a volume of the reinforced thermoplasticmaterial.

In another example, a wheel component is disclosed. The wheel componentcan include a continuous reinforced thermoplastic material and can havea rim bed portion and a main structure portion connected to the rim bedportion. The continuous reinforced thermoplastic material defines acircular cavity therethrough. External surfaces of the wheel componentcan be defined by the rim bed portion and the main structure portion canbe free of indicia associated with a bladder exit from the cavity.

In another example, the indicia can include through portions of thewheel component extending between the circular cavity and an externalenvironment that have a cross-dimension of greater than 15 mm. Further,the external surfaces can cooperate to completely seal the circularcavity from the external environment. The continuous reinforcedthermoplastic material can include a layup of reinforced thermoplasticsections overlapping one another to define a radial crossply. The radialcrossply can extend along a sidewall of the main structure portion.

In another example, the circular cavity can be formed by maintaining apressurized region between the rim bed portion and the main structureportion during a thermal bonding process. The pressurized region can bemaintained without an internal bladder, thereby allowing the externalsurfaces of the rim bed portion and the main structure portion to befree of the indicia typically associated with bladder exit from thecavity.

In another example, the circular cavity is self-sealing. The continuousreinforced thermoplastic material can exhibit a flexural strength of atleast 740 MPa.

In another example, a method of manufacturing a fully reinforcedthermoplastic wheel component is disclosed. The method includes forminga rim bed portion from a first reinforced thermoplastic material. Themethod further includes forming a main structure portion from a secondreinforced thermoplastic material. The method further includes formingthe fully reinforced thermoplastic wheel component as a continuouscircular component by thermally bonding the rim bed portion and the mainstructure portion to one another within a tooling compartment.

In another example, forming the main structure can include defining aradial crossply by arranging a first ply of the second reinforcedthermoplastic material relative to a second ply of the second reinforcedthermoplastic material. One or both of the first or second plies definesa bias angle relative to a center axis of between 22.5 and 75 degrees.The forming of the main structure portion can include stamping thesecond reinforced thermoplastic material to define an inner annularsurface configured for association with a series of spokes.

In another example, the operation of forming the fully reinforcedthermoplastic wheel component can include heating the first and secondreinforced thermoplastic materials above a melting temperature. Formingthe fully reinforced thermoplastic wheel component can further includedefining a cavity between the rim bed portion and the main structureportion by pressurizing a region of the tooling compartmentsubstantially between the rim bed portion and the main structureportion.

In another example, a wheel component is disclosed. The wheel componentincludes a rim bed portion defining an outer annular surface of thewheel component that is configured to engage a bicycle tire. The wheelcomponent further includes a main structure portion defining a cavitywith the rim bed portion. The rim bed portion and the main structureportion are each formed from a reinforced thermoplastic material.Further, the rim bed portion and the main structure are thermally bondedto one another to form an integral structure.

In another example, the main structure portion can define an innerannular surface of the wheel component that can be configured to receivea series of spokes. The series of spokes can be engaged with the mainstructure portion to exhibit a pull force from the wheel component of atleast 300 lbs. Additionally or alternatively, the series of spokes canbe engaged with the main structure portion to exhibit a pull force fromthe wheel component of at least 400 lbs. Additionally or alternatively,the series of spokes can be engaged with the main structure portion toexhibit a pull force from the wheel component of at least 500 lbs.

In another example, the rim bed portion can be seated at least partiallywithin the main structure portion. In some cases, the main structureportion includes a first wall portion and a second wall portion. Thecavity can at least partially be defined by each of the rim bed portion,the first wall portion, and the second wall portion. The first wallportion and the second wall portion can be connected to one another viaa lap joint. Additionally or alternatively, the second wall portion candefine a reinforcing layer along an annular surface defined by the firstwall portion. In some examples, the main structure portion can furtherinclude a third wall portion. In this regard, the cavity can be definedby each of the rim bed portion, the first wall portion, the second wallportion, and the third wall portion.

In another example, the rim bed portion includes a first rim wallportion and a second rim wall portion. The cavity can at least partiallybe defined by each of the first rim wall portion, the second rim wallportion, and the main structure portion.

In another example, the integral structure can define a continuouscircular shape.

In another example, the reinforced thermoplastic material can include athermoplastic material. The reinforced thermoplastic material can alsoinclude fibers held within the thermoplastic material. The fibers caninclude one or more of carbon fibers, glass fibers, Kevlar fibers,and/or basalt fibers. In some examples, the fibers can define at least40% of a volume of the reinforced thermoplastic material. Additionallyor alternatively, the fibers can define at least 70% of the volume ofthe reinforced thermoplastic material. The reinforced thermoplasticmaterial can also include resin-impregnated spread carbon fiber tows, incertain applications.

In another example, the wheel component further includes a spoke portionformed from a reinforced thermoplastic material. The spoke portion canbe thermally bonded with the main structure portion to form the integralstructure as including each of the rim bed portion, the main structureportion, and the spoke portion. In this regard, the wheel component canfurther include a hub portion formed from a thermoplastic material. Thehub portion can be thermally bonded with the spoke portion to form theintegral structure including each of the rim bed portion, the mainstructure portion, the spoke portion, and the hub portion. While manyshapes are possible and described herein, in some examples, the integralstructure can define a tri-spoke shape.

In another example, a wheel component is disclosed. The wheel componentincludes a continuous reinforced thermoplastic material having a rim bedportion and a main structure portion connected to the rim bed portion.The continuous reinforced thermoplastic material defines a circularcavity therethrough. External surfaces of the wheel component aredefined by the rim bed portion and the main structure portion, and arefree of indicia associated with a bladder exit from the cavity.

In another example, the indicia can include through portions of thewheel component that extend between the circular cavity and an externalenvironment, and that have a cross-dimension of greater than 20 mm.Additionally or alternatively, the indicia can include through portionsof the wheel component that extend between the circular cavity and theexternal environment, and that have a cross-dimension of greater than 10mm. The external surfaces cooperate to completely seal the circularcavity from the external environment.

In another example, the circular cavity can be formed by maintaining apressurized region between the rim bed portion and the main structureportion during a thermal bonding process. The pressurized region can bemaintained without an internal bladder, thereby allowing the externalsurfaces of the rim bed portion and the main structure portion to befree of the indicia associated with a bladder exit from the cavity.

In another example, a portion of an inflation component can be withinthe circular cavity and thermally bonded to the main structure portion.The portion of the inflation component can have a melt temperature thatis higher than a melt temperature of the main structure portion. Theportion of the inflation component can have a melt temperature that canbe higher than the main structure portion and a melt temperature of therim bed portion.

In another example, the wheel component can include a film within thecircular cavity. The film can be adapted to define a self-sealingpermanent bladder within the circular cavity. In some examples, the filmcan be formed from a nylon material. The film can have a melttemperature that can be higher than the melt temperature of one or bothof the main structure portion or the rim bed portion.

In another example, the main structure portion can define a reinforcedregion along an inner annular region of the wheel component. Thereinforced region can include multiple reinforced thermoplastic layers,thermally bonded to one another. The main structure portion can includea first wall portion and a second wall portion, each overlapping alongthe inner annular region. In some examples, the reinforced region isconfigured to establish a spoke pull force of at least 500 lbs.

In another example, the continuous reinforced thermoplastic materialincludes fiber filaments suspended in a resin matrix. The fiberfilaments can be arranged in a compacted configuration adjacent oneanother within the resin matrix. The continuous reinforced thermoplasticmaterial includes a nano coating therein surrounding fiber filaments forbinding the filaments to the resin matrix. While many materials arepossible, the fiber filaments can include one or more of carbon fibers,glass fibers, Kevlar fibers, or basalt fibers. In some examples, thecontinuous reinforced thermoplastic material can exhibit a flexuralstrength of at least 740 MPa.

In another example, a method of manufacturing a fully reinforcedthermoplastic wheel component is disclosed. The method includesarranging a rim bed portion and a main structure portion within atooling compartment. The rim bed portion and the main structure portionare formed from a reinforced thermoplastic material. The method furtherincludes pressurizing a region of the compartment that is between therim bed portion and the main structure portion. The method furtherincludes bonding the rim bed portion and the main structure portion byheating the reinforced thermoplastic material above a meltingtemperature. The method further includes sealing a cavity defined by therim bed portion and the main structure portion.

In another example, the operation of heating includes exposing thetooling compartment to a heat source exhibiting a temperature of atleast 450 degree F. The operation of arranging a rim bed portion and amain structure portion within a tooling compartment can include sealingthe rim bed portion at least partially within the main structureportion.

In another example, the main structure portion can include a first wallportion and a second wall portion. In this regard, the operation ofarranging can include overlapping the first wall portion and the secondwall portion along an inner annular surface of the wheel component. Insome examples, the operation of arranging can include mechanicallyengaging each of the first wall portion with a first side of the rim bedportion, and the second wall portion with a second side of the rim bedportion opposite the first side of the rim bed portion. Further, theoperation of bonding can include defining an edge joint along themechanical engagement of each of the first wall portion and the firstside of the rim bed portion, and the second wall portion and the secondside of the rim bed portion.

In another example, the operation of pressurizing includes delivering apressurized fluid into the region of the compartment between the rim bedportion and the main structure portion. The pressurized fluid can beconfigured to maintain the region at a pressure of greater than 40 psi.The pressurized fluid can include compressed air.

In one example, the operation of pressurizing includes maintaining acontour of the region of the compartment that is between the rim bedportion and the main structure portion with a sacrificial material todefine the cavity. In this regard, the operation of sealing can includeallowing the reinforced thermoplastic material to close on itself at apoint of entry for the pressurized fluid delivery. In some examples, themethod further includes plying a higher-melt temperature material to oneor both of the rim bed portion or the main structure portion, prior tothe operation of arranging. The higher-melt temperature material can bea film plied to a consolidated panel or stamp form shape of one or bothof the rim bed portion or the main structure portion.

In another example, the operation of pressurizing can include at leastpartially inserting a portion of the inflation component into the regionof the compartment between the rim bed portion and the main structureportion. The portion of the inflation component can include a consumableadapted to seal the point of entry for the pressurized fluid delivery.Further, the portion of the inflation component can also include athermoplastic material having a melt temperature that is higher than amelt-temperature of the reinforced thermoplastic material used to formthe rim bed portion or the main structure portion. In some examples, theoperation of sealing can include sealing a thermoplastic plug at thepoint of entry.

In one example, the operation of bonding defines an integral structurefrom the rim bed portion and the main structure portion. The integralstructure can be a continuous circular structure.

In another example, a method of manufacturing a fully reinforcedthermoplastic wheel component is disclosed. The method can includeforming a rim bed portion from a first reinforced thermoplasticmaterial, forming a main structure portion from a second reinforcedthermoplastic material, and forming the fully reinforced thermoplasticwheel component as a continuous circular component by thermally bondingthe rim bed portion and the main structure portion to one another withina tooling compartment.

In another example, the operation of forming the rim bed portion caninclude stamping the first reinforced thermoplastic material to definean external annular surface configured to engage a bicycle tire. Theoperation of forming the main structure portion can include stamping thesecond reinforced thermoplastic material to define an inner annularsurface configured for association with a series of spokes.

In another example, the method can further include providing the firstreinforced thermoplastic material and the second reinforcedthermoplastic material from a common reinforced thermoplastic materialhaving fiber tows arranged within a resin material. The fiber tows canbe compacted relative to one another within the resin material. In someexamples, the fiber tows can be arranged as a matrix having a widthsubstantially larger than a height, the matrix defining a spread tow.

In another example, the operation of forming the fully reinforcedthermoplastic wheel component can include heating the first and secondreinforced thermoplastic materials above a melting temperature. Further,the operation of forming the fully reinforced thermoplastic wheelcomponent can include defining a cavity between the rim bed portion andthe main structure portion by pressurizing a region of the toolingcompartment substantially between the rim bed portion and the mainstructure portion. Further, the operation of forming the fullyreinforced thermoplastic wheel component can include arranging the rimbed portion, the main structure portion, and a sacrificial bladder inthe tooling compartment, the sacrificial bladder configured to maintaina pressure in the region of at least 40 psi. In this regard, the methodcan further include removing the sacrificial bladder through at leastone of the rim bed portion or the main structure portion.

In another example, the operation of forming the fully reinforcedthermoplastic wheel component can include reinforcing an inner annularsurface of the continuous circular component. The method can furtherinclude associating a series of spokes with the inner annular surface.In some examples, the reinforced inner annular surface and the series ofspokes cooperate to exhibit a pull force of at least 500 lbs.

In another example, a method of manufacturing a fully reinforcedthermoplastic wheel component is disclosed. The method includes plying afilm to a reinforced thermoplastic material. The film has a highermelting temperature than that of the reinforced thermoplastic material.The method further includes defining a cavity with the reinforcedthermoplastic material and plied film. The method further includessealing the cavity using the film.

In another example, the reinforced thermoplastic material can include aconsolidated panel or a stamp form shape of a rim bed portion or a mainstructure portion. The rim bed portion and the main structure portioncan be arranged to form the fully reinforced thermoplastic wheelcomponent. In this regard, the method can further include stamping theconsolidated panel and the plied film to form the stamp form shape ofthe rim bed portion or the main structure portion.

In another example, the operation of sealing can include allowing apoint of entry for pressurized fluid to close itself, using the film. Inthis regard, the method can further include pressurizing the cavity byat least partially inserting an inflation component through the point ofentry. In some examples, the inflation component can be configured tomaintain a pressure within the cavity of at least 40 psi. The operationof defining can include subjecting the reinforced thermoplastic materialto a thermal bonding process to form an integral structure defining thewheel component.

In another example, the integral structure can be a continuous circularcomponent. The reinforced thermoplastic material can includereinforcement fibers, including one or more of carbon fibers, glassfibers, Kevlar fibers, or basalt fibers.

In another example, a method of manufacturing a fully reinforcedthermoplastic wheel component is disclosed. The method includesarranging a rim bed portion and a main structure portion to define acavity of the fully reinforced thermoplastic wheel component. The methodfurther includes pressurizing the cavity by at least partially insertingan inflation component into the cavity. The inflation component is atleast partially formed from a material having a melting temperaturegreater than a melting temperature of materials used to form the rim bedportion and the main structure portion. The method further includessealing the cavity using the inflation component.

In another example, the operation of sealing can include defining apoint of entry into the cavity for insertion of a portion of theinflation component. The point of entry can be defined through anannular surface defined by the rim bed portion. The operation of sealingcan include co-curing the portion of the inflation component to the mainstructure portion.

In another example, the method further includes severing a portion ofthe inflation component from a remainder of the inflation component, theportion of the inflation component remaining at least partially withinthe cavity. The operation of sealing can include using the portion ofthe inflation component to close the cavity to an external environment.

In another example, the method further includes thermally bonding therim bed portion and the main structure portion to one another. Thethermal bonding can allow external surfaces of the wheel component to beformed free of indicia associated with bladder exit from the cavity,using a portion of the inflation component as a consumable within thecavity.

In addition to the exemplary aspects and embodiments described above,further aspects and embodiments will become apparent by reference to thedrawings and by study of the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements, and in which:

FIG. 1 depicts a sample bicycle;

FIG. 2 depicts detail 1-1 of a wheel assembly of FIG. 1;

FIG. 3A depicts a reinforced thermoplastic rim formed as an integralcircular structure;

FIG. 3B depicts a cross-sectional view of a reinforced thermoplasticmaterial of FIG. 3A used to form the fully thermoplastic rim, takenalong line 3B-3B of FIG. 3A;

FIG. 4 depicts an example of a wheel component formed from a reinforcedthermoplastic material;

FIG. 5A depicts another example of a wheel component formed from areinforced thermoplastic material;

FIG. 5B depicts another example of a wheel component formed from areinforced thermoplastic material;

FIG. 5C depicts another example of a wheel component formed from areinforced thermoplastic material;

FIG. 6 depicts another example of a wheel component formed from areinforced thermoplastic material;

FIG. 7A depicts an operation of forming a rim bed portion of a wheelcomponent;

FIG. 7B depicts an operation of forming a main structure portion of awheel component;

FIG. 7C depicts another operation of forming a main structure portion ofa wheel component;

FIG. 7D depicts an operation of plying a higher melt temperature film toa stamp-formed shape of a wheel component;

FIG. 7E depicts an operation of plying a higher melt temperature film toa consolidated panel prior to a stamping operation;

FIG. 8A depicts an example layup for manufacturing a radial crossply ofa reinforced thermoplastic component;

FIG. 8B depicts a wall portion of a wheel component having a radialcrossply;

FIG. 9A depicts another example layup for manufacturing a radialcrossply of a reinforced thermoplastic component;

FIG. 9B depicts another example layup for manufacturing a radialcrossply of a reinforced thermoplastic component;

FIG. 9C depicts another example layup for manufacturing a radialcrossply of a reinforced thermoplastic component;

FIG. 9D depicts another example layup for manufacturing a radialcrossply of a reinforced thermoplastic component;

FIG. 10A depicts a collection of components used to form a wheelcomponent fully from a reinforced thermoplastic material;

FIG. 10B depicts an assembly for thermally bonding reinforcedthermoplastic components to form a wheel component;

FIG. 10C depicts another assembly for thermally bonding other reinforcedthermoplastic components to form another example of a wheel component;

FIG. 11 depicts a cross-sectional view of the assembly of FIG. 10, takenalong line 11-11 of FIG. 10C;

FIG. 12 depicts an arrangement for pressurizing a cavity of a wheelcomponent with a consumable inflation component;

FIG. 13 depicts a cross-sectional view of the assembly of FIG. 12, takenalong line 13-13 of FIG. 12;

FIG. 14 depicts another assembly for forming a continuous circularcontour of a wheel component;

FIG. 15A depicts a cross-sectional view of an example of a wheelcomponent formed from a reinforced thermoplastic material and havingthermally bonded joints;

FIG. 15B depicts an exploded view of the wheel component of FIG. 15A;

FIG. 16A depicts a cross-sectional view of another example of a wheelcomponent formed from a reinforced thermoplastic material and havingthermally bonded joints;

FIG. 16B depicts an exploded view of the wheel component of FIG. 16A;

FIG. 17A depicts a cross-sectional view of another example of a wheelcomponent formed from a reinforced thermoplastic material and havingthermally bonded joints;

FIG. 17B depicts an exploded view of the wheel component of FIG. 17A;

FIG. 18A depicts a cross-sectional view of another example of a wheelcomponent formed from a reinforced thermoplastic material and havingthermally bonded joints;

FIG. 18B depicts an exploded view of the wheel component of FIG. 18A;

FIG. 19A depicts a cross-sectional view of another example of a wheelcomponent formed from a reinforced thermoplastic material and havingthermally bonded joints;

FIG. 19B depicts an exploded view of the wheel component of FIG. 19A;

FIG. 20A depicts a cross-sectional view of another example of a wheelcomponent formed from a reinforced thermoplastic material and havingthermally bonded joints;

FIG. 20B depicts an exploded view of the wheel component of FIG. 20A;

FIG. 21A depicts an arrangement for performing a spoke weld for areinforced thermoplastic wheel component, according to one example;

FIG. 21B depicts an arrangement for performing a channel weld for thereinforced thermoplastic wheel component of FIG. 21A;

FIG. 22A depicts an arrangement for performing a spoke weld for areinforced thermoplastic wheel component, according to another example;

FIG. 22B depicts an arrangement for performing a channel weld for thereinforced thermoplastic wheel component of FIG. 22A;

FIG. 23A depicts an arrangement for performing a spoke weld for areinforced thermoplastic wheel component, according to another example;

FIG. 23B depicts an arrangement for performing a channel weld for thereinforced thermoplastic wheel component of FIG. 23A;

FIG. 24A depicts an arrangement for performing a spoke weld for areinforced thermoplastic wheel component, according to another example;

FIG. 24B depicts an arrangement for performing a channel weld for thereinforced thermoplastic wheel component of FIG. 24A;

FIG. 25A depicts an arrangement for performing a spoke weld for areinforced thermoplastic wheel component, according to another example;

FIG. 25B depicts an arrangement for performing a channel weld for thereinforced thermoplastic wheel component of FIG. 25A;

FIG. 26 depicts another example of a wheel component formed from areinforced thermoplastic material;

FIG. 27A depicts an apparatus including substantially hollow componentsthat are formed from a thermoplastic material;

FIG. 27B depicts a cross-sectional view of the substantially hollowcomponents of FIG. 27A, taken along line 27B-27B of FIG. 27A;

FIG. 28 depicts a flow diagram of a method of manufacturing a fullyreinforced thermoplastic wheel component;

FIG. 29 depicts a flow diagram of another method of manufacturing afully reinforced thermoplastic wheel component;

FIG. 30 depicts a flow diagram of another method of manufacturing afully thermoplastic wheel component;

FIG. 31 depicts a flow diagram of another method of manufacturing afully thermoplastic wheel component; and

FIG. 32 depicts a flow diagram of a method of forming a sidewall of afully thermoplastic wheel component.

The use of cross-hatching or shading in the accompanying figures isgenerally provided to clarify the boundaries between adjacent elementsand also to facilitate legibility of the figures. Accordingly, neitherthe presence nor the absence of cross-hatching or shading conveys orindicates any preference or requirement for particular materials,material properties, element proportions, element dimensions,commonalities of similarly illustrated elements, or any othercharacteristic, attribute, or property for any element illustrated inthe accompanying figures.

Additionally, it should be understood that the proportions anddimensions (either relative or absolute) of the various features andelements (and collections and groupings thereof) and the boundaries,separations, and positional relationships presented therebetween, areprovided in the accompanying figures merely to facilitate anunderstanding of the various examples described herein and, accordingly,may not necessarily be presented or illustrated to scale, and are notintended to indicate any preference or requirement for an illustratedexample to the exclusion of examples described with reference thereto.

DETAILED DESCRIPTION

The description that follows includes sample systems, methods, andapparatuses that embody various elements of the present disclosure.However, it should be understood that the described disclosure may bepracticed in a variety of forms in addition to those described herein.

The present disclosure describes systems, devices, and techniquesrelated to reinforced thermoplastic components. More specifically, thepresent disclosure describes using reinforced thermoplastic materials toform complex shapes, including shapes having contoured or curvedsurfaces, and/or shapes having a substantially hollow interior. As usedherein, “reinforced thermoplastic materials” can include a variety ofmaterials having reinforcement “fibers” held within a thermoplasticmaterial. As described in greater detail below, this can include, by wayof non-limiting example, certain resin-type or other thermoplasticmaterials that are impregnated with reinforcement fibers, includingcarbon fibers, glass fibers, Kevlar fibers, and/or basalt fibers, amongother options described and contemplated herein. Thermoplastic materialscan exhibit a superior strength-to-weight ratio, and are generallyadaptable to a variety of application-specific shapes. Shapes that havea curved or circular contour and/or a hollow interior can often benefitfrom the strength-to-weight ratio of reinforced thermoplastic materials.Such constructions, however, can be hindered by traditionalmanufacturing techniques.

The systems and techniques of the present disclosure can mitigate suchhindrances and produce reinforced thermoplastic components havingsubstantially smooth, seamless, and consistently curved surfaces.Further, the systems and techniques of the present disclosure canproduce reinforced thermoplastic components having a substantiallyhollow interior. The substantially smooth, seamless, and consistentlycurved surfaces, enhanced by the substantially hollow interior canfacilitate the manufacturing of a wheel component formed from reinforcedthermoplastic materials. More specifically, the systems and techniquesherein can be adapted to facilitate the manufacturing of a wheelcomponent fully from the reinforced thermoplastic materials,substantially free from other filler or support-type materials.

The reinforced thermoplastic material can be used to form an integralstructure. An integral structure can be defined as a one-piecestructure. The integral structure or one-piece or continuous structurecan define a continuous circular shape or a segment thereof. Theintegral structure can thus can adapted to from a bicycle rim, asdescribed in greater detail below. The fully reinforced thermoplasticmaterial can provide a reduced-weight ratio while exhibiting enhancedstrength that can be tailored for high-performance applications. Forexample, the continuous circular structure formed fully from thereinforced thermoplastic material can be tuned to withstand a pull forceof a spoke of an associated series of spokes of at least 300 lbs., of atleast 400 lbs., of at least 500 lbs., or greater as may be appropriatefor a given application. The continuous circular structure can also besubstantially free of indicia or seams or other markings of manufacture,such as that from the removal of a bladder of other sacrificial materialfrom the hollow interior. This can provide an aesthetically pleasingfinish to the wheel component, in addition to supporting overallperformance, for example, by reducing possible failure mechanisms alongthe wheel component, such as where a rim bed and channel wall wouldtypically meet.

While many structural implementations of the wheel component arepossible and described herein, in one example, the wheel componentincludes a rim bed portion that defines an outer annular surface of thewheel component. The outer annular surface is shaped in a manner bywhich to engage a bicycle tire, including being substantially circularor defining a segment of a curve that is adapted to grip an outer tireor wheel component. The wheel component can further include a mainstructure portion that defines a cavity with the rim bed portion. Themain structure portion can be a structural portion of the wheelcomponent that is used, for example, to engage a series of spokes of thewheel component of other features that support the wheel component inoperation. In some cases, the rim bed portion and the main structurecomponent can one or both define a collection of walls or other featuresthat are engageable with one another to form the wheel component, aspresented herein.

Broadly, each of the rim bed portion and the main structure are formedfrom a reinforced thermoplastic material. Where the rim bed portionand/or the main structure include a collection of walls or associatedcomponents, all such components are also formed from a reinforcedthermoplastic material. In this regard, the wheel component can beformed as a fully reinforced thermoplastic wheel component.Thermoplastic materials can be impregnated or more generally combinedwith reinforcement fibers to define the reinforced thermoplasticmaterials, which can have a fiber reinforcement of at least 30%, of atleast 40%, or of at least 70% by volume. In certain examples, thereinforcement fibers can be strategically arranged within thethermoplastic material. For example, the reinforcement fibers can besubjected to a spread treatment during manufacture, or other elongationand orientation technique that allows the reinforced thermoplasticmaterial to define a spread tow, such as a spread carbon fiber tow whencarbon is used as a reinforcement fiber. Other techniques andmodifications to the reinforced thermoplastic materials can be used,including arranging the reinforcement fibers in a matrix, such as in acompacted arrangement. Further, coatings or other treatments can beapplied to fibers prior to (or during) integration with thethermoplastic material to form the reinforced thermoplastic material.This can be a nano-coating that surrounds some or all of the fibers,such as surrounding some or all of individual fibers to define a barrierbetween the fibers and the surrounding thermoplastic material.

In one example, a reinforced thermoplastic material can be used to forma wall portion of the main structure of the wheel component. The wallportion can be formed from a reinforced thermoplastic material that isconstructed from a plurality of plies of reinforced thermoplasticmaterial, such as any of the thermoplastic materials described herein.The plies can be arranged to overlap one another and collectively form aradial pattern to define the wall portion. To illustrate, the radialpattern can include a first ply have a first edge and a second plyhaving a second edge. The first and second plies can overlap oneanother, such as overlapping the first and the second plies such thatthe second edge is arranged substantially transverse to the first edge.Further, the first and second plies can be arranged such that at leastone of the first and second edges defines a bias angle relative to acenter axis of a continuous circle defined by the wheel. Sample biasangles can be between substantially 22.5 and 75 degrees, such as beingsubstantially between 40 and 60 degrees, such as being preferably about45 degrees. The bias angle can be tuned in order to optimize wallstrength, as described herein. The first and second plies can beoverlapped with one another to define an arrangement or grouping ofplies. The wall portion can include a plurality of arrangement of pliesin order to define the radial crossply pattern. The wall portion caninclude multiple layers of crossply laminate, including a 6 layercrossply laminate, with 12, 22, or more overlapping course of tape, asone illustration.

The reinforced thermoplastic materials used to form the wheel componentcan be associated with one another to form an integral structure. As oneexample, a first reinforced thermoplastic material can be used to form arim bed portion of the wheel component and a second reinforcedthermoplastic material can be used to form the main structure portion ofthe wheel component. In certain examples, the first and/or secondreinforced thermoplastic materials can be a sheet, tape, panel, or otherlargely undefined or even partially flexible form. The reinforcedthermoplastic materials can be subjected to one or more machineprocesses in order to define the rim bed portion and/or the mainstructure portion and/or other pieces of the wheel component orcomplex-geometry components of the present disclosure. For example andas described in greater detail below, the reinforced thermoplasticmaterials can be subjected to stamping processes in order to define astamp-formed shape of the rim bed portion, the main structure portion,and/or other portions of the wheel component or other shapes. The stampform shape can generally define application-specific geometries of therim bed portion or the main structure portion, including geometriesadapted to use with a bicycle including the outer annular surfaceadapted to engage a bicycle tire and an inner annular surface configuredto engage a series of spokes of the wheel component.

Thermal bonding can be used to join the rim bed portion and mainstructure portion to one another in order to form the wheel component asan integral structure. The integral structure can be a one-piecestructure. In one example, the rim bed portion and the main structureportion can generally be arranged in a tooling or mold that roughlydefines a target shape of the wheel component. The tooling can besubjected to heat, including subjecting the tooling to heat in excess of450 degrees F.; however, in other cases, the temperature can be more orless than 450 degree F. based on the particular composition of thereinforced thermoplastic material. When exposed to such heat, thethermoplastic material softens and transitions toward a melted orpartially melted state. The thermoplastic material of each of the rimbed portion and the main structure portion transitions toward this statewithin the tooling, where the portions are generally adjacent orcontacting one another. For example, the rim bed portion and the mainstructure portion can be mechanically engaged with one another and/orpressed against a surface of one another in the tooling, such as in atooling compartment. In this regard, upon transitioning toward and intothe partially melted state, the reinforced thermoplastic material of theeach of the rim bed portion and the main structure can generally joinwith one another. For example, the thermoplastic material of the rim bedportion and the thermoplastic material of the main structure portion canat least partially combine or intermix as each approaches or enters apartially melted or fully melted state. The reinforced thermoplasticmaterials can be subsequently cooled, as described herein, allowing eachto return to a more solidified state as a single, integrally formedcomponent from the rim bed portion and the main structure portion. Forexample, the reinforced thermoplastic material can be cooled to definean integral structure. This can allow different components or portionsof the rim (e.g., the rim bed, wall portion, etc.) to collectivelydefine a one-piece, or continuous, and/or seamless structure afterformation.

The thermal bonding process can also be associated with defining asubstantially hollow cavity within the wheel component. The wheelcomponent can have a substantially hollow cavity to reduce weight andimprove stability of the wheel. It is also possible to form a wheel as asubstantially solid structure, such as may be the case for a wheel usedin jogging strollers, carts, luggage, or other applications. Where thewheel component includes the substantially hollow cavity, the systemsand techniques of the present disclosure include establishing andmaintaining a shape of the cavity during the thermal bonding process.This allows the reinforced thermoplastic material to transition towardand into a partially melted or melted state without collapsing ordeforming in a manner that would detract from the formation of aninternal cavity. Maintaining the shape of the cavity can also facilitatethe joining of the reinforced thermoplastic material, for example, byallowing the rim bed portion and the main structure portion to bepressed to together with a sufficient external force to facilitate thegeneral intermixing or combination of the various reinforcedthermoplastic materials without such external force distributing theshape of the cavity. Rather, with the shape of the cavity maintained,the external force of the tooling can also facilitate forming the cavityshape. For example, the rim bed portion and/or the main structureportion can be pressed or manipulated in a manner relative to or againsta sacrificial bladder in order to use the partially melted or meltedform of the reinforced thermoplastic material to establish the internalcavity shape of the wheel component, as one example.

In this regard, in some examples, the sacrificial bladder can be used tofacilitate forming the internal cavity of the wheel component duringthermal bonding. For example, a substantially solid material, includingcertain industrial foams and fillers or consolidated materials can beshaped to define a contour of the internal cavity. Additionally oralternatively, an inflatable bladder can be used, such as an assemblythat can maintain a pressurized region between the main structureportion and the rim bed portion during the thermal bonding process. Therim bed portion and the main structure portion can be associated withthe sacrificial bladder within the tooling assembly prior to the thermalbonding. The sacrificial bladder can be largely heat resistant and/orhave a melting temperature above, or substantially above, that of theheat to which the tooling is subject during the thermal bonding process.In this regard, the sacrificial bladder can retain a solid shape, suchas not being melted or partially melted, while the reinforcedthermoplastic material of the rim bed portion and the main structureportion are melted or partially melted. The rim bed portion and the mainstructure portion can therefore be joined together, as described herein,without collapsing or deforming into an internal cavity defined by therespective portions. The rim bed portion and the main structure portioncan also be joined together without also being inadvertently joined tothe sacrificial bladder.

Subsequent to cooling, the sacrificial bladder can be removed from thewheel component, defining the substantially hollow cavity within thewheel component. Where the wheel component is a segment of a wheel, thesacrificial bladder can be removed from a side of the wheel component.Additionally or alternatively, the sacrificial bladder can be removedfrom a fully formed continuous and enclosed circular component. Forexample, it can be desirable for the sacrificial bladder to remainwithin the wheel segment throughout the formation of multiple wheelcomponent segments to form the wheel component, which can have acontinuous, integral structure that defines a circular shape. Further,the rim bed portion and the main structure portion can be joined to oneanother as a continuous and enclosed circular component, largely leavingthe sacrificial bladder in the wheel component. In this regard, thesacrificial bladder can be removed via a port or hole that can generallybe machined through one or both of the rim bed portion or the mainstructure portion. Subsequent operations can be used to cover or sealthe port or hole and enclose the continuous circular cavity, as may beappropriate for a given application.

The systems and techniques described can also be adapted to maintainand/or establish the internal cavity substantially without the use of asacrificial bladder. Broadly, the systems and techniques describedherein can be used to pressurize a region of a tooling compartment thatis holding the rim bed portion and the main structure during a thermalbonding process. For example, a fluid, such as compressed air, can besupplied to a region of the tooling compartment that is substantiallybetween the rim bed portion and the main structure portion. The fluidcan act to maintain a cavity between the rim bed portion and the mainstructure portion as the reinforced thermoplastic materials are bondedto one another. For example, an inflation component can extend partiallyinto the cavity and supply the compressed air, which can be suppliedwith a pressure of at least 40 psi, of at least 100 psi, of at least 200psi, or greater based on the material properties of the givenapplication. The compressed air can pressurize the tooling compartmentand at least partially hold the rim bed portion and the main structureportion at a desired arrangement within the tooling compartment. As therim bed portion and the main structure portion begin to transitiontoward and into a partially melted or melted state, the pressure withinthe cavity can impede the thermoplastic material from deforming in amanner that would hinder or detract from a contour of the internalcavity. For example, the partially melted or melted reinforcedthermoplastic material would be encouraged away from pressurized zone,and toward the tooling compartment boundaries and\or the respective rimbed portion and main structure portion for thermal bonding therebetween.

As described in greater detail herein, upon cooling, the inflationcomponent can be removed from the internal cavity and the internalcavity can be substantially enclosed from an external environment. Insome cases, this can involve using a plug or other thermoplasticmaterial, which can be reinforced, to thermally bond with the rim bedportion and/or the main structure portion upon exit of the inflationcomponent from the wheel component. Additionally or alternatively, therim bed portion and/or the main structure portion can be substantiallyself-sealing, allowing the point of entry of the inflation component togenerally close in on itself as the inflation component is removed. Incertain examples, this can be facilitated by use of a high-melttemperature film that is plied to one or both of the reinforcedthermoplastic material that forms the rim bed portion and/or the mainstructure portion. For example, the high-melt temperature film can beplied to a consolidated panel or the stamp form shape of the rim bedportion or the main structure portion, in certain examples. The film canhave a melting temperature that is higher than that of the associatedrim bed portion or the main structure portion. In this regard, uponremoval of the inflation component, the associated rim bed portion orthe main structure portion cools, and solidifies according to adifferent thermal profile than that of the film. The film can exhibit amore solid state than the associated rim bed portion or the mainstructure portion for a given temperature. The film can act as aninternal barrier that guides the reinforced thermoplastic material alonga path that closes and seals the point of entry for the inflationcomponent. In certain other examples, as described herein, the inflationcomponent itself can be used to seal the point of entry for thepressurized fluid delivery into the cavity. For example, at least aportion of the inflation component can be formed from a material havinga higher melting temperature than that of the associated rim bed portionor the main structure portion. The portion can be a tip of the inflationcomponent that is introduced in the cavity to supply the pressurize air.The tip can be a consumable feature of the inflation component. Forexample, subsequent to thermal boding of the rim bed portion and themain structure portion, the tip can be severed or otherwise removed froma remainder of the inflation component. The tip or consumable portion ofthe inflation component can in turn be used to seal the point of entryfor the pressurized air. For example, the tip exhibits a higher meltingtemperature than the associated rim bed portion or the main structureportion, and thus cools and solidifies according to a different thermalprofile. This different thermal profile acts to guide the associated rimbed portion or the main structure portion to close and seal the point ofentry for the pressurized air.

With these and other techniques described herein, the resulting wheelcomponent can include a substantially smooth outer contour that can befree of indicia associated with bladder exit from the internal cavity ofthe wheel component. For example, the finished wheel component can havean external surface that can be free of holes that are larger than 20 mmin cross-dimension, and/or free of holes that are larger 10 mm incross-dimension. Such holes could be indications of bladder removal,whereas the absence of such holes can indicate a streamlined,bladderless manufacture of the hollow cavity, as described herein.

It will be appreciated that while the foregoing discussion includesreference to wheel components and other features related to bicycles,this is presented herein as an example implementation of the systems andtechniques for forming intricate and optionally hollow structures fullyfrom a reinforced thermoplastic material or materials. The systems andtechniques provide substantial improvements to existing bicycle-relatedtechnology, for example, by enhancing the strength-to-weight ratio, byincreasing the pull force capabilities of rim, adapting the rim todifferentials in compressive and tensile stresses, and otherimprovements not realized by existing designs. As contemplated herein,the fully reinforced thermoplastic components can be adapted to a widevariety of structures and industries where high-performance is desired.In some cases, this can include adapting the reinforced thermoplasticmaterial to other wheel-related applications, including wheelapplications for strollers, carts, luggage, and other uses. For example,the reinforced thermoplastic material can be used to form a wheel havingan integrally formed tri-spoke shape, which can optionally have aninternal cavity. Other uses are contemplated, including using thereinforced thermoplastic material for applications withaerodynamic-specific shape requirements, such as a blade for a windturbine or a hydrodynamic foil, as examples. Such applications canbenefit from a sufficiently high strength-to-weight ratio, and oftendemand precise external contours, which the techniques of the presentdisclosure can provide. In other examples, other applications arecontemplated herein with the scope of the present disclosure.

Reference will now be made to the accompanying drawings, which assist inillustrating various features of the present disclosure. The followingdescription is presented for purposes of illustration and description.Furthermore, the description is not intended to limit the inventiveaspects to the forms disclosed herein. Consequently, variations andmodifications commensurate with the following teachings, and skill andknowledge of the relevant art, are within the scope of the presentinventive aspects.

As described herein, the reinforced thermoplastic structures can beadapted for use with a bicycle or other apparatus that uses wheels. Inthis regard, FIG. 1 depicts a bicycle 100. The bicycle 100 includeswheel assemblies 108 having a rim 112. The rim 112 can be formed from areinforced thermoplastic material, such as the reinforced thermoplasticmaterials generally discussed above and described in greater detailbelow. This rim 112 can be adapted to withstand dynamic conditionsduring use of the bicycle 100 by a rider, including compressive andtensile stresses at particular localized regions of the rim 112.

As shown in FIG. 1, the composite rim 112 is engaged with a tire 116.The tire 116 can be any appropriate component configured to engage andgrip a riding surface to facilitate forward motion of the bicycle 100,including slim profile tires. As described in greater detail below, thetires 116 can induce various maximum compressive stresses on the rim112. The rim 112 is associated with a series of spokes 114 thatstructurally connect the rim 112 to other components of the bicycle 100.The series of spokes 114 can induce various maximum stresses on the rim112.

In the non-limiting example of FIG. 1, the wheel assembly 108 and rim112 are shown with the bicycle 100. However, it will be appreciated thatthe rim 112 can be used with a variety of bicycles and/or any suitableapparatuses that implement wheels for movement. This can includebicycles with an electric motor, strollers, carts, luggage, and so on.For purposes of illustration, the bicycle 100 is further shown as havinga frame 104, a fork 120, a handle assembly 124, a drive assembly 126,pedals 128, a chain 132, a saddle 136, and a seat post 140. It should benoted that the bicycle 100 can include other components (or variationsof the foregoing components), such as various derailleurs, heat sets,cassettes, brakes, frame tubes of various constructions, and so on. Assuch, the discussion of any bicycle, such as bicycle 100, is meant asillustrative only.

With reference to FIG. 2, detail 1-1 of the wheel assembly 108 is shown.FIG. 2 shows the rim 112 connected with the series of spokes 114 andengaged with the tire 116. The tire 116 is shown contacting a ridingsurface 101. The rim 112 is subjected to various dynamic conditionsduring use of the bicycle 100. Not only do the location of forcesreceived by the rim 112 change as the wheel assembly 108 rotates, theprofile of the forces can be different as well.

In FIG. 2, the rim 112 is shown being subjected to a compressive forceF_(C) and a tensile force F_(T). The compressive force F_(C) can result,for example, from the engagement of the tire 116 with the riding surface101. The tensile force F_(T) can result from the structural engagementdefined by the series of spokes 114 with other components of the bicycle100. In other examples, the rim 112 is subjected to other forces, whichcan change based on the dynamic operating conditions of the bicycle 100.

The rim 112 is formed fully from a reinforced thermoplastic material,such as from any of the reinforced thermoplastic materials describedherein. The reinforced thermoplastic material can be specificallyadapted to increase a strength-to-weight ratio of the rim 112. This canenhance a performance of the rim by not only reducing the overall weightof the wheel assembly 108, but also by selectively providing strength tothe rim 112 in target regions. For example, the series of spokes 114exert various forces on the rim 112 during use of the bicycle 100. Inone example, the rim 112 is adapted, via the reinforced thermoplasticmaterials, to withstand a pull force from one or more of the series ofspokes 114 for high-performance operations. The pull force can beindicative of an amount of force exerted by the spoke on a portion ofthe rim bed, such as a portion where a spoke and the rim 112 are joined.For example, the rim 112 can be adapted to withstand a pull force of atleast 300 lbs. from a spoke of the series of spokes 114, of at least 400lbs. from a spoke of the series of spokes 114, of at least 500 lbs. froma spoke of the series of spokes 114, or greater.

FIG. 3A depicts a rim 300 formed fully from a reinforced thermoplasticmaterial. The rim 300 can be an integral structure having a continuouscircular contour 301. The rim 300 can also be substantially hollowthroughout the continuous circular cavity. The rim 300 can also have asubstantially smooth, seamless exterior surface that is substantiallyfree of any indicia of bladder exit from the internal cavity or otherevidence of intermediate manufacturing processes. Such featurescooperate to define an aesthetically pleasing finish the rim 300.Additionally, such features can reduce potential failure mechanisms byproviding a seamless finish, strengthened by the fibers of thereinforced thermoplastic material.

The rim 300 can include a rim bed portion 304 and a main structureportion 310. The rim bed portion 304 and the main structure portion 310can define an integral structure. For example, the rim bed portion 304and the main structure portion 310 can collectively define a one-piece,or continuous, and/or seamless structure after formation. The rim bedportion 304 is generally configured to engage a bicycle tire. Forexample, the rim bed portion 304 can define an outer annular surface 306that is adapted to receive and retain a bicycle tire. The main structureportion 310 is generally configured to define a channel of the rim 300and is adapted to engage a series of spokes. For example, the mainstructure portion 310 can define an inner annular surface 312 that isadapted to engage a series of spokes 390. The series of spokes 390 canbe connected to a hub 392 or other feature. In this regard, the seriesof spokes 390 can exhibit a pull force on the main structure portion310. The main structure portion 310 can define a reinforced region 314,in certain examples, where the series of spokes 390 and the mainstructure 310 engage one another. The reinforcement region 314 can beformed from additional reinforced thermoplastic materials, selectivelyproviding increased strength and performance.

As shown in the detail view of FIG. 3A, the rim bed portion 304 and themain structure portion 310, while cooperating to define the integrallyformed rim 300, can be provided as two separate components during amanufacturing process. The rim bed portion 304 and the main structureportion 310 can be thermally bonded to one another generally along athermally bonded interface 308. The thermally bonded interface 308 isshown in the detail of FIG. 3A for purposes of illustration. It will beappreciated, however, that while the rim bed portion 304 and the mainstructure portion 310 are provided as individual components during themanufacturing process, the thermally bonding interface 308 can besubstantially invisible to the naked eye in the final product, and assuch, define a seamless interface or transition between the rim bedportion 304 and the main structure portion 310. In this regard, thefinal rim 300 can have a seamless surface 302.

FIG. 3B depicts a cross-sectional view of the rim 300 of FIG. 3A, takenalong line 3B-3B. More particularly, FIG. 3B shows a cross-sectionalview of the reinforced thermoplastic material used to form the rim 300.The rim 300 can be fully formed from the reinforced thermoplasticmaterial. In this regard, the rim bed portion 304, the main structureportion 310, and/or any or all other portions of the rim 300 can beformed from the reinforced thermoplastic materials. It will therefore beappreciated that the following discussion of reinforced thermoplasticmaterials can be applicable to any or all components of the rim 300, ormore generally the wheel components and complex geometric structuresdescribed herein.

FIG. 3B shows the cross-section of the rim 300 as being formed from areinforced thermoplastic material 350. The reinforced thermoplasticmaterial 350 broadly includes reinforcement fibers 354 that are disposedin a thermoplastic material 358. The thermoplastic material 358 isgenerally defined by a material that is softened through the applicationof heat and is conversely hardened when cooled. The thermoplasticmaterial 358 can be heated and cooled multiple, sequential times withoutsubstantial degradation of material properties. Certain resins,polymers, synthetics, nylons, and/or other materials can be used. Thereinforcement fibers 354 provide strength to the thermoplastic material358. For example, the fibers 354 can maintain the shape and physicalstate during the application of heat to the thermoplastic material 358.Sample fibers include carbon fibers, glass fibers, Kevlar fibers, basaltfibers, and/or other appropriate materials that can be adapted toprovide strength to the thermoplastic material 358. In some cases, asshown in the detail of FIG. 3B, the fibers 354, individually orcollectively, can be encased or partially encased in a coating 356. Thecoating 356 can be a nano-coating that defines a barrier between thefibers 354 and the thermoplastic material 358.

The reinforced thermoplastic material 350 can be manufactured in avariety of manners to increase the strength of the material via thearrangement of the fibers 354. For example, in some cases, the fibers354 can be subjected to a spread technique that establishes the fibers354 in the thermoplastic material 358 as a spread tow. In certain cases,this can allow a given cross-section of the reinforced thermoplasticmaterial 350 to have a width 370 that is greater than a height 368.Additionally or alternatively, the spread technique or othermanufacturing technique can arrange the fibers 354 in an elongatedfashion. For example, the fiber 354 can be generally arrangedsubstantially parallel to one another and elongated. Additionally oralternatively, the fibers 354 can define a compact arrangement 362 inthe thermoplastic material 358. The compact arrangement 362 can helporganize the fibers 354 in a manner to increase a density of the fibers354 in the reinforced thermoplastic material 350, by volume. Forexample, for a representative volume 366 of the reinforced thermoplasticmaterial 350, the fibers 354 can define at least 40% of a volume of thematerial 350, at least 70% of a volume of the material 350, or otherappropriate value based on the target strength and application.

FIGS. 4-6 depict sample constructions of wheel components of the presentapplication. A wheel component can be a segment of a wheel or acontinuous circular component. FIGS. 4-6 depict various cross-sectionalviews of the wheel components. The wheel components of FIG. 4-6 can beused to define any of the rims and wheel assemblies described herein,including the rim 112 of FIGS. 1 and 2, and the rim 300 of FIGS. 3A and3B. Further, it will be appreciated that FIGS. 4-6 show the wheelcomponent in a state prior to thermal bonding for purposes ofillustrating the structural relationship of reinforced thermoplasticmaterials used to form the wheel component. Subsequent to a thermalbonding process, such as subsequent to any of thermal bonding processesdescribed herein, the individual reinforced thermoplastic material canjoin to one another in a manner that forms the wheel component assingle, integrally-formed structure.

With reference to FIG. 4, a cross-sectional view of a wheel component400 is shown. The wheel component 400 can be formed fully from areinforced thermoplastic material, such as any of the reinforcedthermoplastic materials described herein, redundant explanation of whichis omitted here for clarity.

The wheel component 400 is shown in FIG. 4 as including a rim bedportion 404 and a main structure portion 410. The rim bed portion 404and the main structure portion 410 cooperate to define a cavity 406. Therim bed portion 404 can define an outer annular surface 408 that isadapted to engage a bicycle tire. The main structure portion 410 candefine an inner annular surface 414 that is adapted to engage a seriesof spokes. The main structure portion 410 can optionally define areinforcement region 414 along some or all of the inner annular surface414. The reinforcement region 416 can be an increased strength region ofthe main structure portion to facilitate increasing the strength to thewheel component 400, such as providing a sufficiently high pull force,as described herein, for high-performance use.

The main structure portion 410 can include a first wall portion 412 aand a second wall portion 412 b. In the example of FIG. 4, the firstwall portion 412 a and the second wall portion 412 b are provided as agenerally single form of reinforced thermoplastic material. The firstand second wall portions 412 a, 412 b can have a thickness 492. In somecases, the thickness 492 can be less than a thickness 490 of the rim bedportion 404; however, this is not required. The main structure portion410 and the rim bed portion 404 can be joined to one another at an edgejoint. In the arrangement of FIG. 4, the main structure portion 410 andthe rim bed portion 404 can collectively define a thickness 494 at theedge. This increased thickness can provide stability to a bicycle tireengaged with the rim bed portion 404.

With reference to FIG. 5A, a cross-sectional view of a wheel component500 is shown. The wheel component 500 can be formed fully from areinforced thermoplastic material, such as any of the reinforcedthermoplastic materials described herein, redundant explanation of whichis omitted here for clarity. The wheel component 500 can besubstantially analogous to the wheel component 400 of FIG. 4 andinclude: a rim bed portion 504, a main structure portion 510, a cavity506, an outer annular surface 508, an inner annular surface 514, a firstwall portion 512 a, a second wall portion 512 b, a reinforced region516, a thickness 592, a thickness 590, and a thickness 594, redundantexplanation of which is omitted here for clarity.

FIG. 5A further shows the first wall portion 512 a and the second wallportion 512 b as being defined by different pieces of reinforcedthermoplastic material. The first wall portion 512 a and the second wallportion 512 b can define an overlap 530 at the reinforcement region 516.The overlap 530 of the first wall portion 512 a and the second wallportion 512 b can enhance the strength of the wheel component 500 at theinner annular surface 514.

Also shown in FIG. 5A, the first wall portion 512 a and the rim bedportion 504 can be joined to one another along a first ridge region 580.For example, the first wall portion 512 a can have an end 572 and therim bed portion 504 can have an end 570. The ends 570, 572 can be joinedto one another using the techniques described herein to form the firstridge region 580. Further, the second wall portion 512 b and the rim bedportion 504 can be joined to one another along a second ridge region582. For example, the second wall portion 512 b can have an end 573 andthe rim bed portion 504 can have an end 571. The ends 571, 573 can bejoined to one another using the techniques described herein to form thesecond ridge region 582. The first and second ridge regions cancooperate to receive a bicycle tire therebetween. In the embodiment ofFIG. 5A, the ends 570, 572 are arranged substantially parallel to oneanother, and with a terminal point of each of respective ends 570, 572substantially unobstructed by the respective one of the first wallportion 512 a or the rim bed portion 504. Further, the ends 571, 573 arearranged substantially parallel to one another, and with a terminalpoint of each of the respective ends 571, 573 substantially unobstructedby the respective one of the second wall portion 512 b or the rim bedportion 504.

In some cases, the ends 570, 571 of the rim bed portion 504 can wraparound the respective ends of the first and second wall portions. Forexample and with reference to FIG. 5B, the end 570 of the rim bedportion 504 wraps at least partially around the end 572 of the firstwall portion 512 a. As further shown in FIG. 5B, the end 571 of the rimbed portion 504 warps at least partially around the end 573 of thesecond wall portion 512 b. Accordingly, the at least partial wrappingcan help modify a performance characteristic of the first and secondridge regions 580, 582, such as enhancing the strength of these regionsor otherwise tailoring the regions for use in particular applications.

In some cases, ends 572, 573 can wrap around the respective ends of therim bed portion 504. For example and with reference to FIG. 5C, the end572 of the first wall portion 512 a wraps at least partially around theend 570 of the rim bed portion 504. As further shown in FIG. 5C, the end573 of the second wall portion 512 b wraps at least partially around theend 571 of the rim bed portion 504. Accordingly, the at least partialwrapping can help modify a performance characteristic of the first andsecond ridge regions 580, 582, such as enhancing the strength of theseregions or otherwise tailoring the regions for use in particularapplications.

With reference to FIG. 6, a cross-sectional view of a wheel component600 is shown. The wheel component 600 can be formed fully from areinforced thermoplastic material, such as any of the reinforcedthermoplastic materials described herein, redundant explanation of whichis omitted here for clarity. The wheel component 600 can besubstantially analogous to the wheel component 400 of FIG. 4 andinclude: a rim bed portion 604, a main structure portion 610, a cavity606, an outer annular surface 608, an inner annular surface 614, a firstwall portion 612 a, a second wall portion 612 b, a reinforced region616, an overlap 630, a first ridge region 680, an end 670, an end 672, asecond ridge region 682, an end 671, an end 673, a thickness 692, athickness 690, and a thickness 694, redundant explanation of which isomitted here for clarity.

Notwithstanding the foregoing similarities, the rim bed portion 604 isshown in FIG. 6 as including a first rim bed portion 604 a and a secondrim bed portion 604 b. The first and second rim bed portions 604 a, 604b can be layered or composite components or layers that are formed withone another in order to define the rim bed portion 604. The dual layerconfiguration of FIG. 6 can help reinforce the outer annular surface608. The thickness 690 can be defined as including a thickness of thefirst rim bed portion 604 a and the second rim bed portion 604 b

FIGS. 7A-7E depict various operations of manufacturing a formed shape ofthe reinforced thermoplastic material. The reinforced thermoplasticmaterial can be initially manufactured as a sheet, a roll, a tape,panel, or the like. According to the techniques described herein, thereinforced thermoplastic material can be manipulated into a shape thatis subsequently used to form the wheel component or othercomplex-geometry shape. For example, the reinforced thermoplasticmaterial can be stamped or pressed into a shape in order to define a rimbed portion, a main structure portion, one or more wall portions, one ormore reinforcement portions, and so on. The stamp-formed shape of thesecomponents can then be mechanically engaged with one another andsubjected to a thermal bonding process to form the continuousintegrally-formed circular structure of the wheel component.

With reference to FIG. 7A, an operation 700 a is shown. At the operation700 a, a stamp form shape of a sample rim bed portion can be formed. Forexample, a reinforced thermoplastic material 708 can be providedsubstantially between a first stamp half 704 and a second stamp half706. The reinforced thermoplastic material 708 can be substantiallyanalogous to any of the reinforced thermoplastic materials describedherein, redundant explanation of which is omitted here for clarity. Thefirst and second stamp halves 704, 706 can be advanced toward thereinforced thermoplastic material 708 in order to press the reinforcedthermoplastic material 708 into the shape of a rim bed portion, such asthat shown in FIG. 7A. To facilitate the foregoing, the reinforcedthermoplastic material 708 can be heated to encourage deformation intothe stamp form shape defined by the first and second stamp halves 704,706.

With reference to FIG. 7B, an operation 700 b is shown. At the operation700 b, a stamp form shape of a sample wall portion can be formed. Forexample, a reinforced thermoplastic material 718 can be providedsubstantially between a first stamp half 714 and a second stamp half716. The reinforced thermoplastic material 718 can be substantiallyanalogous to any of the reinforced thermoplastic materials describedherein, redundant explanation of which is omitted here for clarity. Thefirst and second stamp halves 714, 716 can be advanced toward thereinforced thermoplastic material 718 in order to press the reinforcedthermoplastic material 718 into the shape of a wall portion, such asthat shown in FIG. 7B. To facilitate the foregoing, the reinforcedthermoplastic material 718 can be heated to encourage deformation intothe stamp form shape defined by the first and second stamp halves 714,716.

With reference to FIG. 7C, an operation 700 c is shown. At the operation700 c, a stamp form shape of another sample wall portion can be formed.For example, a reinforced thermoplastic material 728 can be providedsubstantially between a first stamp half 724 and a second stamp half726. The reinforced thermoplastic material 728 can be substantiallyanalogous to any of the reinforced thermoplastic materials describedherein, redundant explanation of which is omitted here for clarity. Thefirst and second stamp halves 724, 726 can be advanced toward thereinforced thermoplastic material 728 in order to press the reinforcedthermoplastic material 728 into the shape of a wall portion, such asthat shown in FIG. 7C, which can be a wall portion configured tocorresponding engagement with the wall portion of FIG. 7B. To facilitatethe foregoing, the reinforced thermoplastic material 728 can be heatedto encourage deformation into the stamp form shape defined by the firstand second stamp halves 724, 726.

In some cases, a film can be plied to the reinforced thermoplasticmaterial to facilitate thermal bonding. For example, a film having ahigher-melt temperature than the reinforced thermoplastic material canbe plied into a stamp-form shape of one or more of the portions of thewheel component and/or a consolidated panel. The different thermalcharacteristics of the film can influence the behavior of the reinforcedthermoplastic material as it begins to cool. For example and asdescribed herein, the reinforced thermoplastic material can beinfluenced to seal or close a hole formed through the material, such asa hole used to provide pressurized air to an internal cavity.

For purposes of illustration, FIG. 7D shows an arrangement 750 having afilm 754 being applied to a stamp form shape 762. The stamp form shape762 can be or define a portion of the rim bed portions or main structureportions described herein. The stamp form shape 762 can define a contour766. The film 764 can be arranged to match the contour 766, and thusexhibit a contour 758 upon being plied with the stamp form shape 762.

FIG. 7E shows an arrangement 780 having a film 784 and a consolidatedpanel 792. The consolidated panel 792 can be a reinforced thermoplasticmaterial, which can be presented in a state prior to stamping into oneor more components of the various wheel assemblies described herein. Theconsolidated panel 792 can define a contour 796, which can besubstantially planar in some instances. The film 784 can be arranged tomatch the contour 796, and thus exhibit a contour 788 upon being pliedwith the consolidated panel 792. The plied consolidate panel 792 and thefilm 784 can in turn be introduced to a stamp or press to form the oneor more components of the wheel assembly as a plied, optionallylaminated structure, having the reinforced thermoplastic material andthe plied higher-melt temperature film.

In some cases, the reinforced thermoplastic material can be formed froma plurality plies. The plies can be arranged relative to one another inorder to define a layup or composite structure that can be used to formone or more portions of the wheel component. As one example, the wallportion of the wheel component can be formed from a plurality of pliesof thermoplastic material. The plurality of plies can be arranged tooverlap one another and collectively form a radial pattern to define thewall portion. One or more or all of the plurality of plies can bearranged or biased relative to a center axis of wheel component. Forexample, a given ply can have an edge that defines an angle with thecenter axis of between substantially 22.5 and 75 degrees, such as beingsubstantially between 40 and 60 degrees, such as being preferably about45 degrees. The bias angle can be tuned in order to optimize wallstrength of the wall portion.

Turning to FIG. 8A, a layup 800 is shown for forming the reinforcedthermoplastic material from a plurality of plies. The layup 800 includesa radial pattern of plies 802. The radial pattern of plies 802 isarranged about a wall portion outline 804. The wall portion outline 804can be generally indicative of a circular shape of the wheel component.In other examples, other outlines and shapes can be used to arrange theplurality of plies. The wall portion outline 804 is shown having acenter 806. The center 806 can define a center axis of the wall portionoutline 804 and/or other generally circular component of the wheelcomponent, including the outer annular surface.

The radial pattern of plies 802 is shown in FIG. 8A as including a firstply 810 and a second ply 820. The first ply 810 includes a first edge812. The second ply 820 includes a second edge 822. The first edge 812can define an angle θ₁ from a center axis defined by the center 806. Thesecond edge 822 can define an angle θ₂ from a center axis defined by thecenter 806. In the example of FIG. 8A, the angles θ₁, θ₂ are shown asbeing substantially 45 degrees. The angles θ₁, θ₂ can define a biasangle or orientation of the plies 810, 820. The angles θ₁, θ₂ can betuned in order to optimize a wall strength of the wheel component, suchas being tunable to be a degree value of substantially between 22.5 and75 degrees, such as being substantially between 40 and 60 degrees, andthe like.

In the example of FIG. 8A, the first ply 810 and the second ply 820 canbe substantially rectangular structures. The first and second plies 810,820 can overlap one another to form a cross pattern with the second edge822 extending over and across the first edge 812. The first and secondplies 810, 820 together can define an arrangement or grouping of plies.In this regard, the radial pattern of plies 802 can include a pluralityof the arrangement of plies 810, 820 to define the radial crossply.Multiple arrangements of plies can be grouped together and layered overone another to define the wall portion. For example, the wall portioncan include multiple layers of crossply laminate, including a 6 layercrossply laminate, with 12, 22, or more overlapping courses of tape,according to one exemplary illustration.

For example, and as show in FIG. 8B, a wall portion 850 is shown formedfrom the layup 800 of FIG. 8A. For example, the radial pattern of plies802 can be plied together and formed into a composite structure. Thecomposite structure having the radially crossply pattern can be shapedor formed into a portion of the continuous wheel component, such asbeing formed into the wall portion. Sample formation techniques incudes,stamping, pressing, molding, thermal forming, and like, as describedthroughout. FIG. 8B shows the composite having the radial cross plypattern of FIG. 8A formed into the wall portion 850. In the formedshaped of the wall portion 850, the first edge 812 and the second edge822 can maintain the bias angles θ₁, θ₂, such as maintain thesubstantially 45 degree value, thereby enhancing wall strength of thecomponent. As noted above, the bias angles can range from a degree valueof substantially between 22.5 and 75 degrees, such as beingsubstantially between 40 and 60 degrees, and the like.

Turning to FIGS. 9A-9D, multiple other example layups of reinforcedthermoplastic components are shown. The layup of FIGS. 9A-9D can be usedto form a wall portion of the wheel component substantially analogouslyto the layup 800 described above with respect to FIGS. 8A and 8B. Asillustrated in FIGS. 9A-9D, the shape, orientation, and number of pliesused to form a wall portion of the wheel component can vary to providedifferent structural properties, geometries, and/or surface finishes.

With reference to FIG. 9A, a first layup 900 a is shown. The first layup900 a includes a radial pattern of plies 910 a. The radial pattern ofplies 910 a are arranged along a wall portion outline 902. The wallportion outline 902 can define a center 906. The radial pattern of plies910 a can include a ply 912 a having a first end 914 a, a second end 916a, and an edge 918 a. The edge 918 a can define a bias angle θ_(9a) froma center axis defined by the center 906. In the example of FIG. 9A, thefirst end 914 a and be different than the second 916 a. For example, thefirst end 914 a can be oriented substantially transverse relative to theedge 918 a, and the second end 916 can extend at an angle greater than90 degrees from the edge 918 a. The radial pattern of plies 910 a aredisposed about the wall portion overlap so that the ends of therespective plies abut one another to define and complete a radialcrossply pattern.

With reference to FIG. 9B, a second layup 900 b is shown. The secondlayup 900 b includes a radial pattern of plies 910 b. The radial patternof plies 910 b are arranged along a wall portion outline 902. The wallportion outline 902 can define a center 906. The radial pattern of plies910 b can include a ply 912 b having a first end 914 b, a second end 916b, and an edge 918 b. The edge 918 b can define a bias angle θ_(9b) froma center axis defined by the center 906. In the example of FIG. 9B, theply 912 b can be rotated relative to a ply layer above or below the ply912 b. For example, the ply 912 b can be rotated in order to overlap anabutting connection of ply below. In this regard, the ply 192 b can berotated to establish a desired connection to the ply below to furthertune the wall strength of the wheel component.

With reference to FIG. 9C, a third layup 900 c is shown. The third layup900 c includes a radial pattern of plies 910 c. The radial pattern ofplies 910 c are arranged along a wall portion outline 902. The wallportion outline 902 can define a center 906. The radial pattern of plies910 c can include a ply 912 c having a first end 914 c, a second end 916c, and an edge 918 c. The edge 918 c can define a bias angle θ_(9c) froma center axis defined by the center 906. In the example of FIG. 9c , thefirst end 914 c can be generally similar to that of the second end 914b. For example, the first and second ends 914 a, 914 b can bereflections of one another and each can extend in generally opposingdirections and at an angle that is greater than 90 degrees from the edge918 c. In this regard, the ply 912 c can be manipulated to establish adesired connection or overlap to an adjacent ply below to further tunewall strength of the wheel component.

With reference to FIG. 9D, a fourth layup 900 d is shown. The fourthlayup 900 d includes a radial pattern of plies 910 d. The radial patternof plies 910 d are arranged along a wall portion outline 902. The wallportion outline 902 can define a center 906. The radial pattern of plies910 d can include a ply 912 d having a first end 914 d, a second end 916d, and an edge 918 d. The edge 918 d can define a bias angle θ_(9d) froma center axis defined by the center 906. In the example of FIG. 9D, thefirst end 914 d can be different than the second 916 d. For example, thefirst end 914 d can be oriented substantially transverse relative to theedge 918 d, and the second end 916 d can extend at an angle greater than90 degrees from the edge 918 d. The radial pattern of plies 910 d aredisposed about the wall portion overlap so that the ends of respectiveplies abut one another to define a complete radial crossply pattern.Further in the example of FIG. 9D, the ply 912 d can be rotated relativeto a ply layer above or below the ply 912 d. For example, the ply 912 dcan be rotated in order to overlap an abutting connection of ply below.In this regard, the ply 192 d can be rotated to establish a desiredconnection to the ply below to further tune wall strength of the wheelcomponent. While FIGS. 9A-9D illustrate various ply layup strategies andconfigurations, any additional configurations, and/or combinations ofthe illustrated ply layup strategies can be used to form the reinforcedthermoplastic material from a plurality of plies.

FIG. 10A depicts a sample wheel component 1000 prior to thermal bonding.The wheel component 1000 can be substantially analogous to the variouswheel components described herein and include: a cavity 10θ₁, a rim bedportion 1004, an outer annular surface 1008, a main structure portion1010, a first wall portion 10112 a, a second wall portion 12 b, and aninner annular surface, redundant explanation of which is omitted herefor clarity.

FIG. 10A also shows the first wall portion 1012 a as defining anengagement feature 1013 a and the second wall portion 1012 b as definingan engagement feature 1013 b. The engagement features 1013 a, 1013 bgenerally overlap one another at the inner annular surface 1014. In thisregard, the engagement features 1013 a, 1013 b can define areinforcement region for the wheel component 1000 along which the wheelcomponent 1000 can be adapted to receive a series of spokes. FIG. 10Aalso shows a sacrificial material 1020. The sacrificial material 1020can help define a shape of the cavity 1001 during a thermal bondingprocess. The rim bed portion 1004, the first wall portion 1012 a, thesecond wall portion 1012 b, and the sacrificial material 1020 are shownmechanically engaged with one another and generally defining a loosefitting connecting. In this configuration, the collection of suchcomponents can be associated with a tooling, where they can be subjectedto heat in order to form thermal bonds among the various reinforcedthermoplastic materials.

In this regard, FIG. 10B shows the wheel component 1000 associatedwithin a tooling 1030. Generally the wheel component 1000, as presentedin FIG. 10A, can be arranged with a tooling compartment 1040. Thetooling 1030 can be subjected to heat in order to transition thereinforced thermoplastic materials to a partially melted or meltedstate, where they can be thermally bonded to one another. For example,in some cases, the tooling 1030 can be subjected to a temperature of atleast 400 degrees F., of at least 450 degrees F., of at least 500degrees F., or other temperature in order to transition the reinforcedthermoplastic materials toward a partially melted or melted state, whichcan be based on the specific material properties of the thermoplastic.

The tooling 1030 operates to maintain and hold the various pieces of thewheel component 1000 relative to one another during the thermal bonding.For example, the tooling 1030 can include a first plate 1032 a, a secondplate 1032 b, and a third plate 1032 c. The plates 1032 a, 1032 b, 1032c can cooperate to enclose the wheel component 1000 within the tooling1030. While the plates 1032 a, 1032 b, 1032 c are shown as segments ofcircular features, it will be appreciated that the plates 1032 a, 1032b, 1032 c can be continuous circular components (as illustrated inphantom in FIG. 10B) that operate to enclose a segmented wheel componentand/or an entire continuous circular wheel component for thermal bondingtherein. The first plate 1032 a can have a contour to engage the firstwall portion 1012 a, the second plate 1032 b can have a contour 1036configured to engage the second wall portion 1012 b, and the third plate1032 c can have a contour 1038 adapted to engage the rim bed portion1004.

The sacrificial material 1020 of FIG. 10B helps maintain the shape ofthe cavity of the wheel component 1000 during the thermal bonding, asdescribed herein. FIGS. 10C and 11 show an example of present disclosurewhere the shape of an internal cavity of the wheel component ismaintained during thermal bonding using pressurized fluid and without abladder. For example, an inflation component can be used to deliver apressurized fluid to regions of tooling that define the internal cavityof the wheel component. Subsequent to thermal bonding, the inflationcomponent can be removed. The reinforced thermoplastic material canclose in and seal itself, in some cases, and/or be adapted to be closedwith other, reinforced thermoplastic components, such as a portion ofthe inflation component that is formed from a reinforced thermoplasticmaterial.

In this regard, FIGS. 10C and 11 shows a wheel component 1080 arrangedgenerally within a tooling 1050. The wheel component 1080 and thetooling 1050 can be generally analogous to those described with respectto FIGS. 10A and 10B and include: a rim bed portion 1084, a first wallportion 1082 a, a second wall portion 1082 b, a first plate 1052 a, asecond plate 1052 b, a third plate 1052 c, a contour 1058, and a contour1056.

The tooling 1050 can also be adapted to provide pressurized fluid to thewheel component 1080 during thermal bonding. In this regard, FIG. 10Cshows the tooling 1050 including an inflation component 1070. Theinflation component 1070 can include an inlet 1072 that is adapted toreceive pressurized fluid, such as compressed air, from a source. Theinflation component 1070 can also include a tip 1074. The tip 1074 isinsertable into the tooling compartment 1060 in order to directpressurized air to a region substantially between the pieces of thewheel component 1080. For example the inflation component 1070 cangenerally extend through the third plate 1052 c so that the tip 1074 isadvanced through the rim bed portion 1084 at an opening 1085. Theinflation component 1070 can be configured to deliver pressurized air tothe tooling compartment 1060 of at least 40 psi, or of at least 100 psi,or of at least 200 psi, and/or delivery at a higher pressure, each ofwhich can be tuned to mitigate the deformation of the reinforcedthermoplastic material into the cavity. To facilitate the foregoing, theinflation component 1070 can also be associated with an adaptor 1087.The adaptor 1087 can be associated with the tip 1074 via an O-ring 1086or other sealing structure. As shown in FIG. 10C, the adaptor 1087 canfit at least partially into the cavity of the wheel component 1080 tofacilitate delivery of the pressurized fluid into the internal cavityand minimize leakages. Subsequent to thermally bonding the reinforcedthermoplastic materials, the tooling 1050 can be allowed to cool and/orbe subjected to an active cooling process. The inflation component 1070can be removed from the wheel component 1080, and the hole 1085 can beclosed. Many mechanisms are possible and described herein. For example,the reinforced thermoplastic materials can be constructed forsubstantially self-sealing of the hole 1085. This can be facilitated bya higher-melt temperature film that can be plied to a stamp form shapeof the wheel components and/or a consolidated panel. In other cases, aseparate plug, patch, or reinforcement strip can be used to close thehole 1085, which can also be formed from a reinforced thermoplasticmaterial. The materials can cool together in a manner that closes thehole 1085 in a seamless fashion, leaving substantially no visibleindication of the hole 1085 in the finished product. In this regard, therim bed portion 1084 and/or the main structure portion 1082 can be fullyformed as reinforced thermoplastic components having a continuouslyhollow cavity and be free of surface indicia of a manufacturing processassociated with bladder exit.

In certain other cases, the inflation component 1070 can be used to seala hole or other point of entry for pressurized air into the cavity. Forexample, FIGS. 12 and 13 present a wheel component 1200 that can have aninternal cavity that is pressurized by an inflation component 1250. Thewheel component 1200 and the inflation component 1250 can besubstantially analogous to the wheel component 1000 and the inflationcomponent 1120 of FIG. 11 and include a main structure portion 1204, afirst wall portion 1208 a, a second wall portion 1208 b a hole 1206, acavity 1210, an inlet or shaft portion 1254, and a tip 1258. Theinflation component 1250 can deliver pressurized air into the cavity1210 via the tip 1258, as shown in FIG. 13. For example, the tip 1258can have a duct 1262 that allows a flow of pressurized air in the cavity1210.

A portion of the inflation component 1250, such as the tip 1262, can bea consumable component that is used to seal the hole 1206. For example,the tip 1262 can be formed from a thermoplastic material (which may ormay not be reinforced) and/or other material that generally has a highermelting temperature than that of the reinforced thermoplastic materialused to form the rim bed portion 1204 and/or the first or second wallportions 1208 a, 1208 b. Subsequent to the thermal bonding of theportions of the wheel component 1200, the tip 1258 can be severed fromthe shaft 1254. The tip 1258 can remain partially integrated with therim bed portion 1204 such as being integrated with the hole 1206 andused to seal and plug the hole 1206. For example, the tip 1258 can coolaccording to a different thermal characteristic than the surround rimbed portion 1204. This differential can encourage the rim bed portion1204 to at least partially close in on itself and seal the hole 1206,using the tip 1258 to plug or block the hole 1206. The cavity 1210 canbe therefore sealed from an external environment. The self-sealingproperties of the rim bed portion 1204 in cooperation with the tip 1258can define a substantially smooth, seamless exterior surface of thewheel component.

As stated above, the pieces of any of the wheel components describedherein can be thermally bonded to one another to form a segment of acontinuous circular shape. Additionally or alternatively, the pieces ofthe wheel components can be thermally bonded to one another to form thecontinuous circular shape. FIG. 14 depicts a sample tooling 1400 that beused to thermally bond the pieces of the wheel component as a continuouscircular shape. In this regard, it will be appreciated that the toolingdescribed with reference to FIGS. 9 and 10 can be, or be adapted todefine, the continuous circular tooling 1400 presented in FIG. 14.

Broadly, FIG. 14 shows the tooling 1400 as including a first plate 1408a and a second plate 1408 b. The tooling 1400 also includes a collectionof annular members 1412. The pieces of the wheel component are arrangedgenerally between the plates 1408 a, 1408 b and the collection ofannular members 1412 encircle the pieces of the wheel component. Theexample of FIG. 14 shows a wheel component 1404 arranged within thetooling 1400. The wheel component 1404 can be substantially analogous toany of the wheel components described herein and include a rim bedportion 1220 and a main structure portion 1224, redundant explanation ofwhich is omitted here for clarity. In some cases, the rim bed portion1220 and the main structure 1224 can be arranged within the tooling 1400and thermally bonded to one another within the tooling 1400.Additionally or alternatively, the wheel component 1404 can includewheel segments 1406 that include rim and main structure portions whichare thermally bonded to one another. In this regard, multiple circularsegments can be arranged with the tooling 1400 in order to define acontinuous circular component, internally formed and having asubstantially seamless exterior.

FIGS. 15A-20B depicts various examples of wheel components that areformed fully from reinforced thermoplastic materials. The wheelcomponents of FIGS. 15A-20B can be formed via a thermal bonding process.For example, one or more components of a rim bed portion and a mainstructure portion that are each formed from a reinforced thermoplasticmaterial can be arranged relative to one another and joined together.The rim bed portion and main structure portion can be constructed in avariety of manners to facilitate thermal bonding. For example, the rimbed portion and the main structure portion can include overlappingportions that are adapted to mechanically engage with one another inorder to form a lap joint. Additionally or alternatively, the rim bedportion and the main structure portion can be adapted to form an edgejoint, among other constructions. In some cases, one or both of the rimbed portion or the main structure portion can be associated with anotherreinforced thermoplastic material, such as a reinforced thermoplasticmaterial that is adaptable to define a reinforced zone of the wheelcomponent that is strengthened to receive spokes or other features of abicycle. It will be appreciated that while FIGS. 15A-20B show sampleconstructions of wheel components, in other cases other constructionsare contemplated herein.

With reference to FIGS. 15A and 15B, a wheel component 1500 is shown.The wheel component 1500 can be substantially analogous to the variouswheel components and the reinforced thermoplastic structures describedherein; redundant explanation of which is omitted here for clarity. Thewheel component 1500 is shown in FIGS. 15A and 15B as including a firstwall portion 1512 a and a second wall portion 1512 b. The first wallportion 1512 a and the second wall portion 1512 b cooperate to enclosethe wheel component 1500 and define a cavity 1506. In the example ofFIGS. 15A and 15B, the first wall portion 1512 a and the second wallportion 1512 b establish the rim bed portion 1504 that defines an outerannular surface of the wheel component 1500 that is configured to engagea bicycle tire. The first wall portion 1512 a and the second wallportion 1512 b also establish the main structure portion 1510 that canbe adapted to engage spokes of a bicycle. The first wall portion 1512 aand the second wall portion 1512 b are mechanically engaged at the rimbed portion 1504 and the main structure portion 1510. For example thefirst wall portion 1512 a can include an engagement feature 1520 a andthe second wall portion 1512 b can include an engagement feature 1520 b.The engagement features 1520 a, 1520 b can overlap one another at therim bed portion 1504, forming a lap joint. Collectively, the overlap ofthe engagement features 1520 a, 1520 b can define a reinforcement region1516 b at the rim bed portion. Further, the first wall portion 1512 acan include an engagement feature 1524 a and the second wall portion1512 b can include an engagement feature 1524 b. The engagement features1524 a, 1524 b can overlap one another at the main structure portion1510, forming a lap joint. Collectively, the overlap of the engagementfeatures 1524 a, 1524 b can define a reinforcement region 1516 a at themain structure portion.

With reference to FIGS. 16A and 16B a wheel component 1600 is shown. Thewheel component 1600 can be substantially analogous to the various wheelcomponents and the reinforced thermoplastic structures described herein;redundant explanation of which is omitted here for clarity. The wheelcomponent 1600 is shown in FIGS. 16A and 16B as including a first wallportion 1612 a, a second wall portion 1612 b, and a rim bed portion1604. The first wall portion 1612 a, the second wall portion 1612 b, andthe rim bed portion 1604 cooperate to enclose the wheel component 1600and define a cavity 1606. In the example of FIGS. 16A and 16B, the rimbed portion 1604 is a structural component that defines an outer annularsurface of the wheel component 1600 that is configured to engage abicycle tire. The first wall portion 1612 a and the second wall portion1612 b establish the main structure portion 1610 that can be adapted toengage spokes of a bicycle. The first wall portion 1612 a and the secondwall portion 1612 b are mechanically engaged at the main structureportion 1610. For example, the first wall portion 1612 a can include anengagement feature 1624 a and the second wall portion 1612 b can includean engagement feature 1624 b. The engagement features 1624 aa, 1624 bcan overlap one another at the main structure portion 1610, forming alap joint. Collectively, the overlap of the engagement features 1624 a,1624 b can define a reinforcement region 1616 at the main structureportion 1610. Further, the first wall portion 1512 a can include anengagement feature 1620 a and the second wall portion 1612 b can includean engagement feature 1620 b. The engagement features 1620 a, 1620 b canbe used to define an edge joint with the main structure portion 1604.For example, the main structure portion 1604 can include an engagementfeature 1605 a that is mechanically engageable with the engagementfeature 1620 a to define an edge joint. The main structure portion 1604can further include an engagement feature 1605 b that is mechanicallyengageable with the engagement feature 1620 b to define another edgejoint.

With reference to FIGS. 17A and 17B a wheel component 1700 is shown. Thewheel component 1700 can be substantially analogous to the various wheelcomponents and the reinforced thermoplastic structures described herein;redundant explanation of which is omitted here for clarity. The wheelcomponent 1700 is shown in FIGS. 17A and 17B as including a rim bedportion 1704 and a main structure portion 1712. The rim bed portion 1704and the main structure portion 1712 cooperate to enclose the wheelcomponent 1700 and define a cavity 1706. In the example of FIGS. 17A and17B, the rim bed portion 1704 is a structural component that defines anouter annular surface of the wheel component 1700 that is configured toengage a bicycle tire. The main structure portion 1710 can be adapted toengage spokes of a bicycle. The rim bed portion 1704 is mechanicallyengaged at the main structure portion 1710. For example, the rim bedportion can include engagement features 1705 a, 1705 b. The mainstructure portion 1712 can include engagement features 1720 a, 1720 b.The engagement features 1720 a, 1705 a can define an edge joint betweenthe main structure portion 1712 and the rim bed portion 1704. Further,the engagement features 1720 b, 1705 b can define an edge joint betweenthe main structure portion 1712 and the rim bed portion 1704. FIG. 17further shows the wheel component as including a reinforcement region1716 at the main structure portion 1712, for example, as might beadapted or strengthened to receive a series of spokes. For example, thewheel component 1700 can further include a reinforcement piece 1718,which can also be formed from a reinforced thermoplastic material. Thereinforcement piece can overlap or cover or be laminated with the mainstructure portion 1712 to define the reinforcement region 1712.

With reference to FIGS. 18A and 18B a wheel component 1800 is shown. Thewheel component 1800 can be substantially analogous to the various wheelcomponents and the reinforced thermoplastic structures described herein;redundant explanation of which is omitted here for clarity. The wheelcomponent 1800 is shown in FIGS. 18A and 18B as including a first wallportion 1812 a, a second wall portion 1812 b, a first rim bed portion1804 a, and a second rim bed portion 1804 b. The first wall portion 1812a, the second wall portion 1812 b, the first rim bed portion 1804 a, andthe second rim bed portion 1804 b cooperate to enclose the wheelcomponent 1800 and define a cavity 1806. In the example of FIGS. 18A and18B, the first rim bed portion 1804 a and the second rim bed portion1804 b establish the rim bed portion 1804 of the wheel component 1800.The rim bed portion 1804 defines an outer annular surface of the wheelcomponent 1800 that is configured to engage a bicycle tire. Further, thefirst wall portion 1812 a and the second wall portion 1812 b establishthe main structure portion 1810 that can be adapted to engage spokes ofa bicycle. The first wall portion 1812 a and the second wall portion1812 b are mechanically engaged at the rim bed portion 1804 and the mainstructure portion 1810. For example, the first wall portion 1812 a caninclude an engagement feature 1824 a and the second wall portion 1812 bcan include an engagement feature 1824 b. The engagement features 1824a, 1824 b can overlap one another at the main structure portion 1810,forming a lap joint. Collectively, the overlap of the engagementfeatures 1824 a, 1824 b can define a reinforcement region 1816 a at therim bed portion 1810. Further, the first rim bed portion 1804 a and thesecond rim bed portion 1804 b can also form a reinforcement region 1816b at the rim bed portion 1804. For example, the first rim bed portion1804 a can include an engagement feature 1818 a and the second rim bedportion 1818 b can include an engagement feature 1818 b. The engagementfeatures 1818 a, 1818 b can overlap one another at the rim bed portion1804, forming a lap joint that defines the reinforcement region 1816 b.The rim bed portion 1804 is also adapted to form edge joints with themain structure portion 1810. For example, the first wall portion 1812 acan include an engagement feature 1820 a and the first rim bed portion1804 a can include an engagement feature 1819 a. The engagement features1820 a, 1819 a can be arranged relative to one another to form the edgejoint. Further, the second wall portion 1812 b can include an engagementfeature 1820 b and the second rim bed portion 1804 b can include anengagement feature 1819 b. The engagement features 1820 b, 1819 b can bearranged relative to one another to form the edge joint.

With reference to FIGS. 19A and 19B a wheel component 1900 is shown. Thewheel component 1900 can be substantially analogous to the various wheelcomponents and the reinforced thermoplastic structures described herein;redundant explanation of which is omitted here for clarity. The wheelcomponent 1900 is shown in FIGS. 19A and 19B as including a first wallportion 1912 a, a second wall portion 1912 b, a rim bed portion 1904,and a shell 1950. The first wall portion 1912 a, the second wall portion1912 b, the rim bed portion 1904, and the shell 1950 cooperate toenclose the wheel component 1900 and define a cavity 1906. In theexample of FIGS. 19A and 19B, the rim bed portion 1904 is a structuralcomponent that defines an outer annular surface of the wheel component1700 that is configured to engage a bicycle tire. Further, the firstwall portion 1912 a, the second wall portion 1912 b, and the shell 1950establish the main structure portion 1910 that can be adapted to engagespokes of a bicycle. The first wall portion 1912 a and the second wallportion 1912 b are mechanically engaged at the main structure portion1910. For example the first wall portion 1912 a can include anengagement feature 1924 a and the second wall portion 1912 b can includean engagement feature 1924 b. The engagement features 1924 a, 1924 b canoverlap one another at the main structure portion 1910, forming a lapjoint. Collectively, the overlap of the engagement features 1924 a, 1924b can define a reinforcement region 1916 a at the rim bed portion 1910.Further, the rim bed portion 1904 can also form reinforcement regions,such as reinforcement regions 1916 b, 1916 c shown in FIGS. 19A and 19B.For example, the first wall portion 1912 a can include an engagementfeature 1920 a that is arrangeable relative to the rim bed portion 1904to define the reinforced region 1916 b. Further, the second wall portion1912 b can include an engagement feature 1920 b that is arrangeablerelative to the rim bed portion 1904 to define the reinforced region1916 b. The reinforced regions 1916 a, 1916 b can be reinforced cornersof the rim bed portion 1904, which can be configured to support and/orenhance the functionality of certain bicycle tires engaged with the rimbed portion 1904. The rim bed portion 1904 is also adapted to form edgejoints with the main structure portion 1910. For example, the shell caninclude an engagement feature 1952 aa and the rim bed portion 1904 caninclude an engagement feature 1905 a. The engagement features 1952 a,1905 a can be arranged relative to one another to form the edge joint.Further, the shell can include an engagement feature 152 bb and the rimbed portion 1904 can include an engagement feature 1905 b. Theengagement features 1952 b, 1905 b can be arranged relative to oneanother to form the edge joint.

With reference to FIGS. 20A and 20B a wheel component 2000 is shown. Thewheel component 2000 can be substantially analogous to the various wheelcomponents and the reinforced thermoplastic structures described herein;redundant explanation of which is omitted here for clarity. The wheelcomponent 2000 is shown in FIGS. 20A and 20B as including a first wallportion 2012 a, a second wall portion 2012 b, a first rim bed portion2004 a, and a second rim bed portion 2004 b. The first wall portion 2012a, the second wall portion 2012 b, the first rim bed portion 2004 a, andthe second rim bed portion 2004 b cooperate to enclose the wheelcomponent 2000 and define a cavity 2006. In the example of FIGS. 20A and20B, the first rim bed portion 2004 a and the second rim bed portion2004 b establish the rim bed portion 2004 of the wheel component 2000.The rim bed portion 2004 defines an outer annular surface of the wheelcomponent 2000 that is configured to engage a bicycle tire. Further, thefirst wall portion 2012 a and the second wall portion 2012 b establishthe main structure portion 2010 that can be adapted to engage spokes ofa bicycle. The first wall portion 2012 a and the second wall portion2012 b are mechanically engaged at the rim bed portion 2004 and the mainstructure portion 2010. For example, the first wall portion 2012 a caninclude an engagement feature 2024 a and the second wall portion 2012 bcan include an engagement feature 2024 b. The engagement features 2024a, 2024 b can overlap one another at the main structure portion 2010,forming a lap joint. Collectively, the overlap of the engagementfeatures 2024 a, 2024 b can define a reinforcement region 2016 a at therim bed portion 2010. Further, the first rim bed portion 2004 a and thesecond rim bed portion 2004 b can also form a reinforcement region 2016b at the rim bed portion 2004. The rim bed portion 2004 is also adaptedto form edge joints with the main structure portion 2010. For example,the first wall portion 2012 a can include an engagement feature 2020 aand the first rim bed portion 2004 a can include an engagement feature2019 a. The engagement features 2020 a, 2019 a can be arranged relativeto one another to form the edge joint. Further, the second wall portion2012 b can include an engagement feature 2020 b and the second rim bedportion 2004 b can include an engagement feature 2019 b. The engagementfeatures 2020 b, 2019 b can be arranged relative to one another to formthe edge joint.

FIGS. 21A-25B depict further examples of thermal bonding of reinforcedthermoplastic components. In particular, FIGS. 21A-25B depictmulti-stage thermal bonding techniques. For example, it can be desirablein certain circumstances to complete a spoke bed bond or weld (e.g.,bonding components of a main structure portion to one another), and inturn complete a channel bond or weld (e.g., bonding components of a rimbed portion to one another and/or with the main structure portion). Itwill be appreciated therefore, that the following techniques can beadapted to thermally bond any of the reinforced thermoplastic materialsto one another, including thermal bonding to form a circular segmentand/or a continuous circular component.

With reference to FIGS. 21A and 21B, a first example of a multi-stagethermal bonding technique is depicted. FIG. 21A shows an operation 2100a in which a spoke bed weld or bond is performed, and FIG. 21B shows anoperation 2100 b in which a channel weld or bond is performed. As shownin FIG. 21A, a main structure portion 2150 can generally be held withina tooling. The tooling can include a first half 2104 a and a second half2104 b. The first and second halves 2104 a, 2104 b can operate as outersupport members that clamp the pieces of the wheel component in thetooling. A first cradle portion 2114 a and a second cradle portion 2114b can contact and engage the main structure portion 2150 within thetooling. An annular member 2106 can retain the main structure portion2150 therein, helping to hold the portion 2150 against the cradles 2114a, 2114 b. A cavity 2152 can be defined by the main structure portion2150 and the annular member 2106. FIG. 21A also shows conduction rings2108 a, 2108 b. The conduction rings 2108 a, 2108 b can be used togenerate heat within the cradle portions 2114 a, 2114 b that can be usedto thermally bond components of the main structure portion 2150 and/orotherwise facilitate a spoke bed weld of the wheel component. Phenolicinsulating rings 2112 a, 2112 b can provide an electrically insulatingfeature that limits the flow of heat to non-target areas during thethermal bonding. With reference to FIG. 21B, the operation 2100 b showsthe thermal bonding of a rim bed portion 2156 to the main structureportion 2150. In the operation 2100 b, heat is generated proximate achannel of the rim bed portion 2156 via conduction rings 2132 a, 2132 b.Phenolic insulting rings 2128 a, 2128 b are provided to limit the flowof heat to non-target areas during the thermal bonding.

With reference to FIGS. 22A and 22B, a second example of a multi-stagethermal bonding technique is depicted. FIG. 22A shows an operation 2200a in which a spoke bed weld or bond is performed, and FIG. 22B shows anoperation 2200 b in which a channel weld or bond is performed. As shownin FIG. 22A, a main structure portion 2250 can generally be held withina tooling. The tooling can include a first half 2204 a and a second half2204 b. The first and second halves 2204 a, 2204 b can operate as outersupport members that clamp the pieces of the wheel component in thetooling. A first cradle portion 2214 a and a second cradle portion 2214b can contact and engage the main structure portion 2250 within thetooling. An annular member 2206 can retain the main structure portion2250 therein, helping to hold the portion 2250 against the cradles 2214a, 2214 b. The annular member 2206 can also extend toward and pushagainst the main structure portion 2250 to help define contour 2253during thermal bonding. FIG. 22A also shows conduction rings 2208 a,2208 b. The conduction rings 2208 a, 2208 b can be used to generate heatwithin the cradle portions 2214 a, 2214 b that can be used to thermallybond components of the main structure portion 2250 and/or otherwisefacilitate a spoke bed weld of the wheel component. Phenolic insulatingrings 2212 a, 2212 b can provide an electrically insulating feature thatlimits the flow of heat to non-target areas during the thermal bonding.With reference to FIG. 22B, the operation 2200 b shows the thermalbonding of a rim bed portion 2256 to the main structure portion 2250. Acavity 2252 can be defined by the main structure portion 2250 and therim bed portion 2256. In the operation 2200 b, heat is generatedproximate a channel of the rim bed portion 2256 via conduction rings2232 a, 2232 b. Phenolic insulting rings 2228 a, 2228 b are provided tolimit the flow of heat to non-target areas during the thermal bonding.

With reference to FIGS. 23A and 23B, a third example of a multi-stagethermal bonding technique is depicted. FIG. 23A shows an operation 2300a in which a spoke bed weld or bond is performed, and FIG. 23B shows anoperation 2300 b in which a channel weld or bond is performed. As shownin FIG. 23A, a main structure portion 2350 can generally be held withina tooling. The tooling can include a first cradle portion 2314 a, asecond cradle portion 2314 b, a third cradle portion 2314 c, and afourth cradle portion 2014 d, each of which cooperate to contact andengage the main structure portion 2350 within the tooling. A cavity 2352can be defined by the main structure portion 2350 and the third andfourth cradles 2314 c, 2314 d. FIG. 23A also shows conduction rings 2308a, 2308 b. The conduction rings 2308 a, 2308 b can be used to generateheat with the cradle portions 2314 a, 2314 b that can be used tothermally bond components of the main structure portion 2350 and/orotherwise facilitate a spoke bed weld of the wheel component. Phenolicinsulating rings 2312 a, 2312 b can provide an electrically insulatingfeature that limits the flow of heat to non-target areas during thethermal bonding. With reference to FIG. 23B, the operation 2300 b showsthe thermal bonding of a rim bed portion 2356 to the main structureportion 2350. In the operation 2300 b, heat is generated proximate achannel of the rim bed portion 2356 via conduction rings 2332 a, 2332 b.Phenolic insulting rings 2328 a, 2328 b are provided to limit the flowof heat to non-target areas during the thermal bonding.

With reference to FIGS. 24A and 24B, a fourth example of a multi-stagethermal bonding technique is depicted. FIG. 24A shows an operation 2400a in which a spoke bed weld or bond is performed, and FIG. 24B shows anoperation 2400 b in which a channel weld or bond is performed. As shownin FIG. 24A, a main structure portion 2450 can generally be held withina tooling. The tooling can include a first cradle portion 2414 a and asecond cradle portion 2414 b, each of which cooperate to contact andengage the main structure portion 2450 within the tooling. A cavity 2452can be defined by the main structure portion 2450 and the cradles 2414a, 2414 b. FIG. 24A also shows conduction rings 2408 a, 2408 b. Theconduction rings 2408 a, 2408 b can be used to generate heat with thecradle portions 2414 a, 2414 b that can be used to thermally bondcomponents of the main structure portion 2450 and/or otherwisefacilitate a spoke bed weld of the wheel component. Phenolic insulatingrings 2412 a, 2412 b can provide an electrically insulating feature thatlimits the flow of heat to non-target areas during the thermal bonding.With reference to FIG. 24B the operation 2400 b shows the thermalbonding of a rim bed portion 2456 to the main structure portion 2450. Inthe operation 2400 b, heat is generated proximate a channel of the rimbed portion 2456 via conduction rings 2432 a, 2432 b. Phenolic insultingrings 2428 a, 2428 b are provided to limit the flow of heat tonon-target areas during the thermal bonding.

With reference to FIGS. 25A and 25B, a fifth example of a multi-stagethermal bonding technique is depicted. FIG. 25A shows an operation 2500a in which a spoke bed weld or bond is performed, and FIG. 25B shows anoperation 2500 b in which a channel weld or bond is performed. As shownin FIG. 25A, a main structure portion 2550 can generally be held withina tooling. The tooling can include a first half 2504 a and a second half2504 b. The first and second halves 2504 a, 2504 b can operate as outersupport members that clamp the pieces of the wheel component in thetooling. A first cradle portion 2514 a and a second cradle portion 2514b can contact and engage the main structure portion 2550 within thetooling. An annular member 2506 can retain the main structure portion2550 therein, helping to hold the portion 2550 against the cradles 2514a, 2514 b. A cavity 2552 can be defined by the main structure portion2550 and the annular member 2506. FIG. 25A also shows conduction rings2508 a, 2508 b. The conduction rings 2508 a, 2508 b can be used togenerate heat with the cradle portions 2514 a, 2514 b that can be usedto thermally bond components of the main structure portion 2550 and/orotherwise facilitate a spoke bed weld of the wheel component. Phenolicinsulating rings 2512 a, 2512 b can provide an electrically insulatingfeature that limits the flow of heat to non-target areas during thethermal bonding. With reference to FIG. 25B, the operation 2500 b showsthe thermal bonding of a rim bed portion 2556 to the main structureportion 2550. In the operation 2500 b, heat is generated proximate achannel of the rim bed portion 2556 via conduction rings 2532 a, 2532 b.Phenolic insulting rings 2528 a, 2528 b are provided to limit the flowof heat to non-target areas during the thermal bonding. FIG. 25B alsoshows another annular member 2507 that is used to hold the rim bedportion 2556 adjacent the main structure portion 2550. The anotherannular member 2507 can be adapted to define a contoured surface thatmatches and/or is used to form a matching contour of the rim bed portion2556, such as that used to engage a bicycle tire.

Turning to FIG. 26, a wheel component 2600 is shown. The systems andtechniques of the present disclosure can be used to produce a widevariety of shapes and components from reinforced thermoplastic material.This can include shapes and components having curved contours and/orsubstantially hollow interiors, such as the various wheel components andassemblies described herein. The systems and techniques can also be usedto produce another wheel designs, such as the wheel component 2600 whichcan substantially define a tri-spoke shape.

For example, the wheel component 2600 can have a rim 2604 with asubstantially circular contour that defines an outer perimeter of thewheel component 2600. The rim 2604 can be smooth and substantiallyseamless, according to the various methods described herein. The wheelcomponent can also include a series of spokes 2608. The spokes 2608 canbe integrally formed with the rim 2604 and associated therewith at oneor more curved regions 2620. While the series of spokes 2608 includesfive spokes in FIG. 26, it will be appreciated that the series of spokes2608 more generally cooperate to define the tri-spoke design of thewheel component 2600. In this regard, the series of spokes 2608 caninclude three spokes, integrally formed with the rim 2604. The wheelcomponent 2600 can also include a hub 2624. The hub 2624 can beintegrally formed with some or all of the series of spokes 2608 andassociated therewith at one or more curved regions 2624. The hub candefine an opening 2616 that is adapted to receive a component of abicycle.

The wheel component 2600 can be formed fully from a reinforcedthermoplastic material. In this regard, each of the rim 2604, the seriesof spokes 2608, and the hub 2612 can be formed from a reinforcedthermoplastic material. The rim 2604, the series of spokes 2608, and thehub 2612 can be bonded to one via any of the thermal bonding processesdescribed herein. In some cases, one or more of the rim 2604, the seriesof spokes 2608, and the hub 2612 can be formed as a substantially hollowcomponent.

It is contemplated and described herein that the systems and techniquesfor forming a component from reinforced thermoplastic materials can beused to construct a wide variety of applications where a sufficientlyhigh strength-to-weight ratio is desired. For example, the systems andtechniques described herein can be adapted to produce components thathave a sealed, hollow interior and/or define a complex, seamlessexterior contour. As one illustration, FIGS. 27A-27B depict theapplication of systems and techniques described herein to wind turbines,and wind turbine blades. It will be appreciated, however, that theexample of FIGS. 27A-27B is meant as an illustration of other non-wheelapplications of the systems and techniques described herein rather thanbe limiting.

With reference to FIG. 27A, a wind turbine 2700 is shown. The windturbine 2700 can include blades 2704 that are associated with arotatable structure 2708. The wind turbine 2700 can further include adevice 2712 that is connected to the rotatable structure 2708 and isconfigured for energy transfer upon the rotation of the rotatablestructure 2708. The blade 2704 can be sufficiently strong to withstandthe force of wind and gravitational forces, but light in order torotate. The blades 2704 can be formed full from a reinforcedthermoplastic material, according to one or more the techniquesdescribed herein.

For example, with reference to FIG. 27B, a cross-sectional view of theblade 2704 is depicted, taken along line 27B-27B of FIG. 27A. The blade2704 can have an external contour 2750 that is substantially smooth andseamless, according to the techniques described herein. The blade 2704can further include a cavity 2752. The cavity 2752 can be substantiallysealed from an external environment. The blade 2704 can be formed tomeet target aerodynamic specifications, and as such defining a leadingedge 2756 and a trailing edge 2758. One or both of the leading edge 2756or the trailing edge 2758 can be curved or partially curved. Further,one or both of the leading edge 2765 or the trailing edge 2758 candefine a sharp edge of the blade 2704. The reinforced thermoplasticmaterial can be tuned to have a thickness 2754.

To facilitate the reader's understanding of the various functionalitiesof the examples discussed herein, reference is now made to the flowdiagram in FIGS. 28, 29, 30, and 31, which illustrates processes 2800,2900, 3000, and 3100, respectively. While specific steps (and orders ofsteps) of the methods presented herein have been illustrated and will bediscussed, other methods (including more, fewer, or different steps thanthose illustrated) consistent with the teachings presented herein arealso envisioned and encompassed with the present disclosure.

In this regard, with reference to FIG. 28, process 2800 relatesgenerally to a method of manufacturing a fully reinforced thermoplasticwheel component. The process 2800 can be used with any of the wheelcomponents and tooling described herein, for example, such as the wheelcomponents 300, 400, 500, 600, 800, 1000; and the tooling 900, 1050,1200; and variations and combinations thereof.

At operation 2804, a rim bed portion and a main structure portion can bearranged within a tooling compartment. The rim bed portion and the mainstructure portion can be formed from a reinforced thermoplasticmaterial. For example and with reference to FIGS. 10A and 10B, the rimbed portion 1004 and the main structure portion 1010 can be arranged inthe tooling compartment 1040. The rim bed portion 1004 and the mainstructure portion 1010 can be formed from a reinforced thermoplasticmaterial, such as any of the reinforced thermoplastic materialsdescribed herein, redundant explanation of which is omitted here forclarity.

At operation 2808, a region of compartment that is between the rim bedportion and the main structure portion can be pressurized. For exampleand with reference to FIG. 10C, the tooling compartment 1060 can bepressurized. The inflation component 1070 can deliver a compressed airto a region of the tooling 1050 that is substantially between the rimbed portion 1084 and the main structure portion 1080 to maintain a shapeof a cavity of the wheel component during thermal bonding.

At operation 2812, the rim bed portion and the main structure portioncan be bonded by heating the reinforced thermoplastic material above amelting temperature. For example and with reference to FIG. 11, the rimbed portion 1084 and the first wall portion 1082 a and second wallportion 1082 b can be thermally bonded to one another. For example, thetooling 1050 can be subjected to heat, such as heat that is an excess of450 degrees, that causes one or more of the main structure portion 1084,the first wall portion 1082 a, and/or the second wall portion 1082 b totransition toward or into a partially melted or melted state.

At operation 2816, a cavity can be defined by the rim bed and the mainstructure portion and the cavity can be sealed. For example and withreference to FIG. 11, the cavity of the wheel component 1050 can besealed. Subsequent to thermal bonding of the pieces of the wheelcomponent 1110, the inflation component 1170 can be removed from thecavity. In some cases, the opening 1085 can be allowed to close withexit of the inflation component 1170. For example, the reinforcedthermoplastic material of the rim bed portion 1004 can be largelyself-sealing. Additionally or alternatively, a higher-temp film, plug orother structure can cooperate to seal the opening 1085.

In this regard, with reference to FIG. 29, process 2900 relatesgenerally to a method of manufacturing a fully reinforced thermoplasticwheel component. The process 2900 can be used with any of the wheelcomponents and tooling described herein, for example, such as the wheelcomponents 300, 400, 500, 600, 800, 1000; and the tooling 900, 1050,1200; and variations and combinations thereof.

At operation 2904, a rim bed portion can be formed from a firstreinforced thermoplastic material. For example and with reference toFIG. 7A, the rim bed portion 708 can be formed from a firstthermoplastic material. A stamping operation can manipulate the firstthermoplastic material into the shape of the rim bed portion 708.

At operation 2908, a main structure portion can be formed from a secondreinforced thermoplastic material. For example and with reference toFIGS. 7B and 7C, the wall portions 718, 728 can be formed from a secondthermoplastic material. A stamping operation can manipulate the secondthermoplastic material into the shape of the wall portions 718, 728.

At operation 2912, the fully reinforced thermoplastic wheel componentcan be formed as a continuous circular component. The operation offorming can occur by thermally bonding the rim bed portion and the mainstructure portion to one another within a tooling compartment. Forexample and with reference to FIG. 14, the rim bed portion 1220 and themain structure portion 1224 can be mechanically engaged with oneanother. The rim bed portion 1220 and the main structure portion 1224can be mechanically engaged with one another and arranged within atooling 1200, which can define a continuous circular shape therein. Thetooling 1200 can be subjected to heat, allowing the rim bed portion 1220and the main structure portion 1224 to thermally bond to one anothertherein. The rim bed portion 1220 and the main structure portion 1224can be removed from the tooling 1200 as an integrally formed structurehaving a continuous, substantially seamless exterior contour.

In this regard, with reference to FIG. 30, process 3000 relatesgenerally to a method of manufacturing a fully reinforced thermoplasticwheel component. The process 3000 can be used with any of the wheelcomponents and tooling described herein, for example, such as the wheelcomponents 300, 400, 500, 600, 800, 1000; and the tooling 900, 1050,1200; and variations and combinations thereof.

At operation 3004, a film can be plied to a reinforced thermoplasticmaterial. The film can have a higher melting temperature than that ofthe reinforced thermoplastic material. For example and with reference toFIG. 7D, the film 754 can be plied to a stamp form shape 762. The film754 can have a higher melting temperature than that of the stamp formshape 762, which is formed from a reinforced thermoplastic material.Further, as shown in FIG. 7E, the film 784 can be plied to theconsolidated panel 792. The film 784 can have a higher meltingtemperature than that of the consolidated panel 792.

At operation 3008, a cavity can be defined with the reinforcedthermoplastic material and the plied film. For example and withreference to FIGS. 8 and 9, the cavity 801 can be defined using thecollection of the rim bed portion 804 and the main structure portion810, all of which can be formed from a reinforced thermoplastic materialhaving a plied higher-melt temperature film.

At operation 3012, the cavity can be sealed using the film. For exampleand with reference to FIG. 11, the rim bed portion 1004 can include thehigher-melt temperature film described herein. In this regard, thereinforced thermoplastic material of the rim bed 1004 and the film coolaccording to a different thermal characteristic. The different thermalcharacteristic can allow the rim bed portion 1004 to be substantiallyself-sealing, closing the hole 1005 upon cooling.

In this regard, with reference to FIG. 31, process 3100 relatesgenerally to a method of manufacturing a fully reinforced thermoplasticwheel component. The process 3000 can be used with any of the wheelcomponents and tooling described herein, for example, such as the wheelcomponents 300, 400, 500, 600, 800, 1000; and the tooling 900, 1050,1200; and variations and combinations thereof.

At operation 3104, a rim bed portion and a main structure portion can bearranged to define a cavity of the fully reinforced thermoplastic wheelcomponent. For example and with reference to FIGS. 12 and 13, the rimbed portion 1204 and the walls 1208 a, 1208 b can be arranged to definethe cavity 1210. The rim bed portion 1204 and the walls 1208 a, 1208 bcan be arranged to define the cavity 1210 within a tooling that isadapted to form a thermal bond between the pieces held therein.

At operation 3108, the cavity can be pressurized by at least partiallyinserting an inflation component into the cavity. The inflationcomponent can at least partially be formed from a material having amelting temperature that is greater than a melting temperature ofmaterials used to form the rim bed portion and the main structureportion. For example and with reference to FIGS. 12 and 13, the cavity1210 can be pressurized by at least partially inserting an inflationcomponent 1250 into the cavity 1210. In particular, the tip 1258 can beinserted through an opening 1206 and used to direct compressed air intothe cavity 1201 in order to maintain a shape of the cavity 1210 during athermal bonding process. The tip 1258 can be at least partially formedfrom a material having a melting temperature that is greater than amelting temperature of the rim bed portion 1204.

At operation 3112, the cavity can be sealed using the inflationcomponent. For example and with reference to FIGS. 12 and 13, the tip1258 can be separated from a remainder of the inflation component 1250,such as separating the tip 1258 from the shaft portion 1254. The tip1258 can remain at least partially engaged within the hole 1206,defining a plug or partial plug for the flow of air therethrough.Additionally, the tip 1262 can cool according to a different thermalcharacteristic than that of the reinforced thermoplastic material of therim bed portion 1204. The different thermal characteristic can allow therim bed portion 1204 to be substantially self-sealing, closing the hole1005 upon cooling with the tip 1262.

With reference to FIG. 32, process 3200 relates generally to a method ofmanufacturing a wall portion of a fully reinforced thermoplastic wheelcomponent. The process 3200 can be used with any of the wheel componentsand tooling described herein, for example, such as the wheel components300, 400, 500, 600, 800, 1000; and the tooling 900, 1050, 1200; andvariations and combinations thereof.

At operation 3204, a first ply of reinforced thermoplastic material isprovided. For example, and with reference to FIG. 8A, the first ply 810is provided. The first ply 810 can include or be formed from areinforced thermoplastic material, such as any of the materialsdescribed herein. The first ply 810 can have a first edge 812. The firstply 810 can be provided relative to the wall portion outline 804. Forexample, the first ply 810 can be arranged relative to the wall portionoutline 804 to define an angle θ₁ from a center axis of the circularoutline, as defined by the center 806.

At operation 3208, a second ply of reinforced thermoplastic material isprovided. For example, and with reference to FIG. 8B, the second ply 820is provided. The second ply 820 can include or can be formed from areinforced thermoplastic material, such as any of the materialsdescribed herein. The second ply 820 can have a second edge 822. Thesecond ply 820 can be provided relative to the wall portion outline 804.For example, the second ply 820 can be arranged relative to the wallportion outline 804 to define an angle θ₂ from a center axis of thecircular outline, as defined by the center 806.

At operation 3212, the first ply and the second ply are overlappedwithin one another in order to define an arrangement of plies. Forexample, and with reference to FIGS. 8A and 8B, the first ply 810 andthe second ply 820 are overlapped with one another to define anarrangement of plies of the radial pattern 802. In one example, thefirst and second plies 810, 820 are overlapped with one another suchthat the first edge 812 and the second edge 822 are substantiallytransverse to one another. It will be appreciated, however, that theorientation of the first and second edges 812, 822 can be specificallychosen and/or designed with any appropriate orientation to facilitatewall strength of the wheel component.

At operation 3216, a plurality of the arrangement of plies are providedto define a radial pattern of a wheel component of a wall portion. Forexample, and with reference to FIGS. 8A and 8B, multiple groupings orarrangements of the plies 810, 820 can be provided and arranged radiallyalong the outline 804. The radial arrangement of the plies 810, 802 candefine the radial cross pattern 802, such as that shown with referenceto FIG. 8A. The layup 800 including the crossply pattern 802 can besubsequently shaped to form the wall portion 850, according to any ofthe shaping techniques described herein.

Other examples and implementations are within the scope and spirit ofthe disclosure and appended claims. For example, features implementingfunctions can also be physically located at various positions, includingbeing distributed such that portions of functions are implemented atdifferent physical locations. Also, as used herein, including in theclaims, “or” as used in a list of items prefaced by “at least one of'indicates a disjunctive list such that, for example, a list of “at leastone of A, B, or C” means A or B or C or AB or AC or BC or ABC (i.e., Aand Band C). Further, the term “exemplary” does not mean that thedescribed example is preferred or better than other examples.

The foregoing description, for purposes of explanation, uses specificnomenclature to provide a thorough understanding of the describedexamples. However, it will be apparent to one skilled in the art thatthe specific details are not required in order to practice the describedexamples. Thus, the foregoing descriptions of the specific examplesdescribed herein are presented for purposes of illustration anddescription. They are not targeted to be exhaustive or to limit theexamples to the precise forms disclosed. It will be apparent to one ofordinary skill in the art that many modifications and variations arepossible in view of the above teachings.

1. A wheel component, comprising: a rim bed portion at least partiallydefining a cavity and defining an outer annular surface, the outerannular surface configured to engage a bicycle tire; and a mainstructure portion at least partially defining the cavity; wherein: therim bed portion comprises a reinforced thermoplastic material; the mainstructure portion comprises a reinforced thermoplastic material; and therim bed portion is bonded to the main structure portion to form anintegral structure.
 2. The wheel component of claim 1, wherein: the mainstructure portion comprises a wall portion formed from the reinforcedthermoplastic material, and the reinforced thermoplastic material of thewall portion comprises a plurality of overlapping plies defining aradial crossply.
 3. The wheel component of claim 2, wherein: theplurality of overlapping plies comprises a first ply having a firstedge; and the first edge defines a bias angle of between 22.5 and 75degrees relative to a radius extending from the outer annular surface toa center axis of a continuous circle defined by the outer annularsurface.
 4. The wheel component of claim 3, wherein: the plurality ofoverlapping plies comprises a second ply having a second edge; and thesecond ply overlaps the first ply with the first edge orientedsubstantially transverse to the second edge.
 5. The wheel component ofclaim 4, wherein: the first ply and the second ply define an arrangementof plies; the wheel component further comprises a plurality of thearrangement of plies disposed in a radial pattern; and the plurality ofthe arrangement of plies defines the wall portion.
 6. The wheelcomponent of claim 1, wherein the rim bed portion and main structureportion are at least one of thermally bonded, chemically bonded, oradhesively bonded.
 7. The wheel component of claim 1, wherein: the mainstructure portion defines an inner annular surface that is configured toreceive a series of spokes; and the main structure portion is configuredto withstand a pull force of a spoke of the series of spokes of at least300 lbs.
 8. The wheel component of claim 7, wherein the main structureportions defines a reinforcing layer along the inner annular surface. 9.The wheel component of claim 1, wherein: the reinforced thermoplasticmaterial comprises: a thermoplastic material; and fibers disposed withinthe thermoplastic material; and the fibers include at least one ofcarbon fibers, glass fibers, Kevlar fibers, or basalt fibers.
 10. Thewheel component of claim 9, wherein the fibers define at least 30% of avolume of the reinforced thermoplastic material.
 11. A wheel component,comprising a continuous reinforced thermoplastic material, thecontinuous reinforced thermoplastic material defining: a rim bed portionhaving a first external surface; a main structure portion connected tothe rim bed portion and having a second external surface; and a circularcavity; wherein the first external surface and the second externalsurface are each free of indicia associated with bladder exit from thecavity.
 12. The wheel component of claim 11, wherein the indiciacomprises through portions of the wheel component extending between thecircular cavity and an external environment that have a cross-dimensionof greater than 15 millimeters (mm).
 13. The wheel component of claim12, wherein the first external surface cooperates with the secondexternal surface to seal the circular cavity from an externalenvironment.
 14. The wheel component of claim 11, wherein the continuousreinforced thermoplastic material comprises a layup of overlappingreinforced thermoplastic sections, the layup defining a radial crossply.15. The wheel component of claim 14, wherein the radial crossply extendsalong a sidewall of the main structure portion.
 16. The wheel componentof claim 11, wherein the circular cavity is formed by maintaining apressurized region between the rim bed portion and the main structureportion during a thermal bonding process.
 17. The wheel component ofclaim 11, wherein the circular cavity comprises a self-sealing film. 18.The wheel component of claim 11, wherein the continuous reinforcedthermoplastic material exhibits a flexural strength of at least 740 MPa.19-24. (canceled)
 25. A wheel component, comprising: a wall portionformed from a reinforced thermoplastic material, wherein the reinforcedthermoplastic material of the wall portion comprises a plurality ofoverlapping plies defining a radial crossply, and a rim bed portiondefining a cavity with the wall portion.
 26. The wheel component ofclaim 25, wherein the wall portion comprises a first wall portion and asecond wall portion connected to one another via a lap joint.
 27. Thewheel component of claim 26, wherein the second wall portion defines areinforcing layer along an annular surface defined by the first wallportion.
 28. The wheel component of claim 26, wherein the cavity is atleast partially defined by each of the rim bed portion, the first wallportion, and the second wall portion.
 29. The wheel component of claim26, wherein the rim bed portion and the first wall portion are joined toone another to define a first ridge region, the rim bed portion and thesecond wall portion are joined to one another to define a second ridgeregion, and the first and second ridge regions are configured to receivea bicycle tire therebetween.
 30. The wheel component of claim 25,wherein the rim bed portion is bonded to the main structure portion toform an integral structure that defines a continuous circular shape.